Thrust Washer Selection

Whenever side gears or pinion mate gears are replaced, select suitable thrust washers as follows:
1. Clean side gears and pinion mate gears using a suitable solvent.
2. Before assembling gears, apply hypoid gear oil to frictional surfaces.
3. Install previously removed thrust washer on right side gear. On left side gear, install a suitable thrust washer.
4. Temporarily tighten differential cases using two screws.
5. Position differential assembly so right side gear is on upper side. Place a .0012 inch feeler gauge between right side gear and thrust washer.
6. Do not insert feeler gauge in oil groove portion of differential case.
7. Also place a 0.0012 inch additional feeler gauge between right side gear and thrust washer so it is positioned diagonal to feeler gauge placed in step 5.
8. Rotate right side gear with a suitable tool attached to splines. If right side gear cannot be rotated, replace thrust washer used on left side gear with a thinner one.
9. Replace both feeler gauges with 0.0039 inch gauges. At this point, ensure right side gear does not rotate. If it does, replace thrust washer on left side gear with a thicker one so right side gear does not rotate.
10. As explained in above step, select suitable thrust washers to ensure the following:
a. Both side gears rotate (0.0012 inch feeler gauges are used).
b. Side gear is held stationary (0.0039 inch feeler gauges are used).