Differential setup instructions

[Astro95]

I'm posting this over here because the other board keeps truncating my messages down to one sentence. This in response to Roy's request for help rebuilding his axle:

Differential Setup Instructions

1)  Remove the carrier from the axle housing.
2)  Pull side bearings off and grind the ID to allow for a slip fit.
3)  Measure pinion rotating torque and remove.
4)  R&R pinion bearing.  Use old pinion bearing inner cage as an installation
tool to press new pinion bearing on.
5)  Install new ring gear onto carrier.
6)  Install carrier into housing without any shims.
7)  Mark a measuring point on ring gear.  
8)  Set a dial indicator against ring gear.
9)  Slide carrier back and forth in housing to measure total required shim
pack.  Record measurement.
10)  Remove carrier.
11)  Install pinion gear, crush sleeve, bearing and all hardware.
12)  Set pinion bearing preload.
13)   Reinstall carrier and dial indicator.  Slide carrier back and forth and
take measurement at same point as before.  Subtract new measurement from old
measurement.  The difference determines the thickness of the shim pack to be
installed on the ring gear side of the carrier.  
14)  Remove carrier.
15)  Install remainder of shims on opposite side plus .015 inches for bearing
preload.
16)  Reinstall carrier and torque bearing caps.
17)  Set up dial indicator on ring gear teeth and measure backlash.
18)  If backlash is incorrect, move shims to correct.
19)  Once backlash is correct, run gear pattern with paint.
20)  Once pattern is correct, remove carrier and install new bearings.

[rlsllc]

That's really cool, Thanks!!

[Astro95]

You're welcome. I copied it right off my Dish Network DVR. I was watching Xtreme 4X4 and saw it. I backed it up to the beginning and wrote all the steps down pausing it long enough to catch up on my writing. That was the best step by step explaination I've ever seen so I knew I had to save it for future reference.