We are about ready to assemble the finished product. Place the differential assembly in the case along with the bearing races. Apply anti-seize to the adjuster nut threads and slide the adjuster nuts into the threads in the bearing saddles in the case. Then install the main caps observing proper orientation and torque the main cap bolts to 85 ft-lbs for an iron case and to 80 ft-lbs for an aluminum case.

Before installing the pinion support assembly, a 0.017" thick depth shim was chosen as a starting point.  Slide the pinion support into the case with the depth shim and secure in place with the five pinion support bolts. Note: The bolt pattern of the pinion support is not symmetric, therefore, it will only install in one orientation. For an iron case torque pinion support bolts to 45 ft-lbs. and for an aluminum case torque bolts to 35 ft-lbs.

You are now ready to set the “backlash.” Begin by tightening the driver’s side adjuster nut until there is zero backlash between the ring gear and the pinion gear. Once this starting point is achieved, we will set the backlash by tightening the passenger side adjuster nut. This will accomplish two things. The first being to move the ring gear away from the pinion creating backlash and the second is to place preload on the differential bearings.  Here’s a little tip to remember: When rotating the adjuster nuts, make sure a stopping point is reached in which a hole in the nut lines up with the adjuster nut locking tab.

The next step is to measure backlash. Place a dial indicator on the drive side of any ring gear tooth. Zero the indicator and then rotate the gear back and forth without moving the pinion. Backlash must be between 0.008"-0.010". If it does not fall in this range rotate the adjuster nuts accordingly. Backlash must be checked at three points around the ring gear and should not vary by more than 0.003".