Express 2500 V8-6.6L DSL Turbo (2010)
10. Install the pinion in the pinion gear bearing retainer.
11. Install the drive pinion flange/yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair).
Note: Do not apply sealant to the pinion gear bearing retainer at this time.
12. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth.
13. Install the pinion gear bearing retainer to the axle housing.
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution).
14. Install the pinion bearing retainer bolts and tighten to 88 Nm (65 lb ft).
15. Using an inch-pound torque wrench, measure the rotational torque of the pinion it should be between 1.0-2.3 Nm (10-20 lb in) for used bearings,
or 1.7-3.4 Nm (15-30 lb in) for new bearings.
16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, use the J 8614-01 -
remover and continue to tighten the pinion nut in small increments until the rotational torque is between 1.0-2.3 Nm (10-20 lb in) for used
bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings.
17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated.
Recheck the rotating torque and adjust if necessary.
18. Install the differential assembly. Refer to Differential Replacement (10.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear
Drive Axle/Differential Replacement (10.5 Inch Axle)) Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) (See: Service and Repair/Removal
and Replacement/Rear Drive Axle/Differential Replacement (8.6, 9.5/9.5 LD Inch Axles)).
19. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Differential Carrier Bearing Preload Adjustment (9.5LD Inch Axle)) Differential Carrier
Bearing Preload Adjustment (10.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Differential Carrier Bearing
Preload Adjustment (10.5 Inch Axle)) Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and
Replacement/Rear Drive Axle/Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle)).
20. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (9.5LD Inch Axle) (See: Service and
Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (9.5LD Inch Axle))Pinion Depth Adjustment (8.6 Inch Axle) (See:
Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (8.6 Inch Axle))Pinion Depth Adjustment (10.5 Inch
Axle) (See: Service and Repair/Removal and Replacement/Rear Drive Axle/Pinion Depth Adjustment (10.5 Inch Axle)).
21. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear Drive
Axle/Backlash Adjustment (8.6 Inch Axle)) Backlash Adjustment (9.5 LD Axle) (See: Service and Repair/Removal and Replacement/Rear Drive
Axle/Backlash Adjustment (9.5 LD Axle)) Backlash Adjustment (10.5 Inch Axle) (See: Service and Repair/Removal and Replacement/Rear
Drive Axle/Backlash Adjustment (10.5 Inch Axle)).
22. Fill the axle with lubricant. Refer to Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and
Replacement/Differential Oil Replacement (9.5LD Inch Axle)) Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service
and Repair/Removal and Replacement/Differential Oil Replacement (8.6 Inch Axle)) Differential Oil Replacement (10.5 Inch Axle) (See: Fluid -
Differential/Service and Repair/Removal and Replacement/Differential Oil Replacement (10.5 Inch Axle)).
23. Remove the support and lower the vehicle.
