m. Differential Case Assemble

^ Tools Required
- J 22919 Bearing Installer

IMPORTANT: Lubricate the bearing inner and outer race surfaces before assembly.

1. Install the following parts into the differential case:
^ The pinion gears
^ The pinion gear thrust washers
^ The side gears
^ The side gear thrust washers
^ The pinion shaft
^ The pinion shaft roll pin

2. Measure the differential side gear backlash using a feeler gauge. The differential side gear backlash should fall within 0.03-0.08 mm (0.0012-0.0031 inch).
^ If the differential side gear backlash is greater than 0.08 mm (0.0031 inch), select larger size side gear thrust washers in order to bring the differential side gear backlash within the specification.
^ If the differential side gear backlash is less than 0.03 mm (0.0012 inch), select smaller size side gear thrust washers in order to bring the differential side gear backlash within the specification.

CAUTION: When handling parts that have been preheated for installation purposes, always wear leather welding gloves with a minimum amount of handling time. If this precaution is not observed, severe skin bums or personal injury may result.

IMPORTANT: Heat the new Vehicle Speed Sensor (VSS) ring in an approved preheat oven just prior to installation. DO NOT use an acetylene torch or other open flame. Always allow preheated parts to cool after installation. DO NOT quench preheated parts with water. Use compressed air in order to help cool any preheated parts.

3. Preheat the Vehicle Speed Sensor (VSS) ring to approximately 95°C (200°F).
4. Install the new (VSS) ring onto the differential case.
5. Install the right differential side bearings onto the differential case using the J 22919 and a press.

IMPORTANT: Heat the differential ring gear in an approved preheat oven just prior to installation. DO NOT use an acetylene torch or other open flame. Always allow preheated parts to cool after installation. DO NOT quench preheated parts with water. Use compressed air in order to help cool any preheated parts.

6. Preheat the differential ring gear to approximately 50-100°C (122-212°F).
7. Install the differential ring gear onto the differential case.
8. Install the ten differential ring gear bolts.
^ Tighten the ten differential ring gear bolts to 107 Nm (79 ft. lbs.).

NOTICE: Refer to Service Precautions in Cautions and Notices.

9. Install the left differential side bearing using the J22919 and a hydraulic press.