Workman HDX Auto Page 4 − 47 Drive Train
7. Install all components to differential assembly (items
20 to 29):
A. Apply a coating of 80W90 API GLI−5 gear oil to all
surfaces of pinion and output gears.
B. Slide output gear (item 23) into differential hous-
ing and then position both pinion (item 27) gears into
housing making sure that pinion gears mesh properly
with output gear.
C. Slide differential gear pin (item 26) into differential
housing and pinion gears. Make sure that dowel pin
holes in gear pin and differential housing align.
D. Secure differential gear pin into the differential
housing with new dowel pin (item 25).
E. Slide output gear (item 22) into spiral gear bore.
IMPORTANT: The cap screws (item 20) used to
secure the spiral gear to the differential housing
have a patch lock on the threads to prevent loos-
ening of the screws. Either replace screws or ap-
ply medium strength thread locker to threads of
original screws before assembly.
F. Position spiral gear (item 21) to the differential
housing making sure that output gear meshes prop-
erly with pinion gears. Secure spiral gear with eight
(8) cap screws. Torque screws in a crossing pattern
from 54 to 59 ft−lb (74 to 80 N−m).
NOTE: To make sure that shift fork (item 32) and shim
(item 11) are properly positioned, assembly of the differ-
ential is easiest if components are assembled onto the
output cover.
8. Install gear case to output cover:
A. Support output cover on work bench with the shift
fork facing up.
B. Place shim (item 11) and then engagement dog
(item 2) on cover centered on bearing. Make sure
that shift fork engagement tabs are positioned in en-
gagement dog groove.
C. Slide differential assembly onto the pins on the
engagement dog. Make sure that shim, engagement
dog and differential assembly stay centered over
bearing in output cover.
D. Make sure gasket sealing surfaces of output cov-
er and gear case are thoroughly cleaned. Install both
dowel pins (item 9) to the supported output cover.
E. Apply silicone sealant to mating surfaces of out-
put cover
F. Lower gear case onto the output cover and align
dowel pins to locate gear case.
G. Secure output cover to gear case with eight (8)
flange head screws. Torque screws from 15 to 20 ft−
lb (21 to 27 N−m).
9. Apply multi−purpose grease to seal lips and the area
between the seal lips on output shaft seals (items 34 and
35). Carefully install output shaft seals into output cover
and gear case. The seals should fully seat past the
chamfer on the casting.
10.By inserting a clean screwdriver into solenoid hole in
output cover, make sure that shift fork pivots freely.
Then, install compression spring (item 17) and solenoid
(item 33) into cover. Torque solenoid to 20 ft−lb (27
N−m).
11.Make sure that 18.6 fluid ounces (550 milliliter)
(approximate) of new 80W90 API GLI−5 gear oil is
added to rear differential before vehicle operation.
12.Install and torque fill and drain plugs from 16 to 19 ft−
lb (21 to 25 N−m).
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Drive Train
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