Specifications

Driver-Controlled Main Differential Lock
96 MAINTENANCE MANUAL
16. Connect a volt-ohm meter to the sensor
switch. Select ohms on the meter. Rotate the
switch CLOCKWISE until the meter reading
changesfrominnitytolessthanoneohm.
Turn the switch one additional turn and tight-
en the locknut to 25-35 lb-ft (35-45 Nm).
Differential Lock Assembly Cover Plates
For differentials without the differential lock or
air shift, assemble the sensor switch plug and
cover plate as follows.
Fixed capscrew DCDL Cover Plate As-
semblies
1. Install the washer and plug into the hole for
the sensor switch. Tighten the plug from
45-55 lb-ft (60-74 N m). Figure 6.32.
.
2. Apply silicone gasket material to the cover
plate mounting surface on the differential.
See the Section 4.
3. Install the four washers and capscrews.
Tighten the capscrews to 7.4-8.9 lb-ft (10-
12 N m). Figure 6.32.
Threaded DCDL Cover Plate Assemblies
1. Apply Loctite 518 liquid adhesive to the
plate threads.
2. Install the bolts and washers and tighten the
plate into the differential opening to 7.5-9.0
lb-ft (10-12 N m).
Differential Assembly Into the Forward
AxleHousing
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 manufac-
turer’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alkalineso-
lutions correctly. Read the manufacturer’s in-
structions before using hot solution tanks and
alkaline solutions. Then carefully follow the in-
structions.
NOTE:
When you install the differential into the axle
housing, the shift collar must be held in the en-
gaged position. This can be done by keeping
the air pressure applied to the shift cylinder by
using the manual engaging capscrew. See the
the procedure in this section. The differential
must be in the locked or engaged position to
install the differential assembly into the axle
housing. After you install the differential into
the axle housing, shift the differential into the
unlocked or disengaged position to permit the
installation of the left-hand axle shaft.
Manual Method
1. Use a cleaning solvent and rags to clean
the inside of the axle housing and the dif-
ferential mounting surface. See the Section
4.
2. Check the axle housing for damage. If neces-
sary, repair or replace the housing. See the
Section 4.
3. Check for loose studs in the differential mount-
ing surface. Remove and replace the studs
where required. Apply liquid adhesive to the
holes. Install and tighten the stud to 150-230
lb-ft (204-312 N m).
4. The differential lock must be manually en-
gaged before installing the differential into the
housing. See the the procedure in this section.
SENSOR
SWITCH
PLUG
WASHER WASHER
CAPSCREW
CAPSCREW COVER
PLATE (APPLY
SILICONE GASKET
MATERIAL)
THREADED COVER PLATE
(APPLY LOCTITE 518
ADHESIVE TO COVER
PLATE THREADS)
Figure 6.32