Locking Differential Assemble 8.6 Inch, 9.75 Inch Axles

Important: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the locking differential can be assembled.

1. Measure the left and right side gear backlash and thrust block. Refer to Locking Differential Adjustment .



2. Install the locking differential clutch disc thrust washer into the left side or flange-end of the differential case.



3. Install the locking differential side gear cam unit and clutch disc assembly into the left side or flange-end of the differential case.
4. Install the differential side gear shim into the right side or bell-end of the differential case.



5. Install the differential side gear and clutch disc assembly into the right side or bell-end of the differential case.




Important: If the original pinion gears and thrust washers are being re-used, install the pinion gears and thrust washers on the same side as when removed.

6. Install the pinion gear and the pinion thrust washers.

Place the pinion gears and the pinion thrust washers 180 degrees apart.

7. Rotate the pinion gears and the pinion thrust washers 90 degrees and align the pinion gears with the pinion shaft opening in the differential case.



8. Install the thrust block.

The open side of the thrust block must face the window opening.




9. Install the pinion shaft.



10. Install the new pinion shaft lock bolt.

Tighten the pinion shaft lock bolt finger tight.




11. Install the governor assembly.



12. Install the latching bracket assembly.

The straight end of the latching bracket spring must be over and outside the governor assembly shaft.




13. Install the latching bracket bushing.
14. Install the governor assembly bushing.



15. Drive the governor bushing into position using a hammer and a brass drift.

Specification
Press the bushing into place until there is 0.25-1.27 mm (0.010-0.050 in) of shaft end play.

16. Drive the latching bracket bushing into position using a hammer and a brass drift.

Specification
Press the bushing into place until there is 0.000-0.051 mm (0.000-0.002 in) of shaft end play.

Notice: Refer to Fastener Notice in the Preface section.

17. Tighten the pinion shaft lock bolt.

Tighten

•	For the 8.6 inch axle, tighten the pinion shaft lock bolt to 36 N·m (27 lb ft).

•	For the 9.75 inch axle, tighten the pinion shaft lock bolt to 27 N·m (20 lb ft).

18. Install the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
19. Install the differential side bearings. Refer to Differential Side Bearings Replacement .
20. Install the differential assembly. Refer to Differential Replacement .

Locking Differential Assemble 10.5 Inch Axle

Important: The left and right side gear backlash and thrust block thickness measurement must be completed before the components of the differential can be assembled.

1. Install the differential side gear shim into the right side or bell-end differential case half.



2. Install the differential side gear clutch disc assembly into the right side or bell-end differential case half.



3. Install the differential side gear into the right side or bell-end differential case half.



4. Install the locking differential clutch disc thrust washer into the left side or flange-end differential case half.



5. Install the locking differential cam unit and clutch disc assembly into the left side or flange-end differential case half.



6. Install the governor assembly.



7. Install the latching bracket and spring assembly.

The straight end of the latching bracket spring must be over and outside the governor assembly shaft.




8. Install the locking differential spider, the differential pinion gears, and the differential pinion gear thrust washers into the differential case.



9. Install the thrust block.



10. Install the right case half to the left case half.

Hold the right side locking differential side gear and clutch disc assembly in the right side case half.

Align the governor and latching bracket assembly shaft with the holes in the left case half.

Notice: Refer to Fastener Notice in the Preface section.




11. Install the differential case bolts.

Tighten
Tighten the differential case screws to 50 N·m (37 lb ft).

12. Install the ring gear. Refer to Drive Pinion and Ring Gear Replacement .
13. Install the differential side bearings. Refer to Differential Side Bearings Replacement .
14. Install the differential assembly. Refer to Differential Replacement .