Differential Assembly: Reassembly

If reusing parts, position spacers in original location on back of differential side gears. Install gears in differential case. If using new parts, install spacers of medium thickness, on new side gears and install in case. See DIFFERENTIAL GEAR SPACE THICKNESS .
Place washers behind pinion gears and mesh both pinions with side gears while rotating pinions to slip them in place. Install pinion shaft. Measure backlash between pinion and side gears. See Fig 1 .

Fig 1: Checking Pinion and Side Gear Backlash
Courtesy of CHRYSLER CORP., INC.
Backlash should be .003" (.076 mm). Install spacers on both sides to arrive at proper backlash which must be equal for both sides. With proper backlash obtained, install pinion shaft lock pin.
NOTE: Always use new lock washers when reassembling ring gear.
Press bearings on both ends of differential carrier, applying load to inner race only. Install ring gear to case. Apply lock sealant to only 12 mm bolt threads. Tighten bolts in criss-cross pattern to specifications and secure with lock washer tabs.

DIFFERENTIAL GEAR SPACE THICKNESS