Specifications

79
Assembly and Installation
MAINTENANCE MANUAL
CAUTION
USE A PRESS AND A SLEEVE OR FORK IN-
STALLATION TOOL TO INSTALL THE FORK.
DO NOT USE A HAMMER OR MALLET. USING
A HAMMER OR MALLET CAN DAMAGE THE
BEARINGS, FORK OR FLANGE.
If a fork is removed after it has been partially
or fully installed, the unitized pinion seal will
be damaged. Remove and discard the original
unitized pinion seal and replace it with a new
one.
If a fork has been installed into the unitized pinion
seal and then removed, the inner sleeve of the
seal will be damaged. Install a new seal.
3. Use a press and sleeve or an installation
tooltoinstalltheforkorangeintheoutput
shaft. Verify that the splines inside the fork
orangearealignedwiththesplinesonthe
toutput shaft. If a press and sleeve are used,
verify that the output shaft is supported.
4. Install the nut that fastens the output fork or
angetotheoutputshaft.Placeaholdingtool
ontheforkorangeandtightenthenuttothe
speciedtorque.SeetheSection8.
5. Rotate the fork at least one full turn af-
ter the fork nut is tightened to the correct
torque specication. This ensures correct
seating of the seal.
Differential Assembly of the Axle Housing
WARNING
Solvent cleaners can be ammable, poisonous
and cause burns. Examples of solvent cleaners
are carbon tetrachloride, and emulsion type and
petroleum base cleaners. Read the manufactur-
er’s instructions before using a solvent cleaner,
then carefully follow the instructions. Also follow
the procedures below:
•Wearsafeeyeprotection.
•Wearclothingthatprotectsyourskin.
•Workinawellventilatedarea.
•Donotusegasoline,orsolventsthatcontain
gasoline. Gasoline can explode.
• Youmustuse hot solution tanks or alka-
line solutions correctly. Read the manu-
facturer’s instructions before using hot so-
lution tanks and alkaline solutions. Then
carefully follow the instructions
1. Use a cleaning solvent and rags to clean the
inside of the axle housing and the differential
mounting surface. See the Section 4.
2. Inspect the axle housing for damage. Repair or
replace the axle housing. See the Section 4.
3. Check for loose studs, if equipped, in the
mounting surface of the housing where the
differential fastens. Remove and clean
the studs that are loose.
4. Install the studs in the axle housing. See the pro-
cedure in this section. Tighten the studs to 150-
230 lb-ft (203-312 Nem).
.
WARNING
When you apply some silicone gasket materials,
a small amount of acid vapor is present. To pre-
ventseriouspersonalinjury,ensurethatthework
area is well-ventilated. Read the manufacturer’s
instructions before using a silicone gasket ma-
terial, then carefully follow the instructions. If a
silicone gasket material gets into your eyes, fol-
low the manufacturer’s emergency procedures.
Have your eyes checked by a physician as soon
as possible.
CAUTION
APPLY SILICONE GASKET MATERIAL IN A
CONTINUOUS 0.25-INCH (6 MM) BEAD. IF YOU
USE MORE THAN THIS AMOUNT, GASKET
MATERIAL CAN BREAK OFF AND PLUG LU-
BRICATION PASSAGES. DAMAGE TO COM-
PONENTS CAN RESULT.
5. Apply a 0.25-inch (6 mm) continuous bead of
silicone gasket material to the mounting sur-
face of the housing where the differential fas-
tens. Figure 5.102.
0,25” (6MM) DIAMETER
SILICONE GASKET BEAD
Figure 5.102