9.75 Inch, 10.5 Inch Axles

Pinion Depth Adjustment (9.75 Inch, 10.5 Inch Axles)

Tools Required
^ J22536 Pinion Driver
^ J24433 Pinion Cone and Side Bearing Installer
^ J34925 Pinion Setting Gage and Components
^ J45692 Pinion Shim Selector Kit - Dana Axles
^ J45710 Pinion Bearing Oil Seal Installer
^ J8001 Dial Indicator Set
^ J8614-01 Flange and Pulley Holding Tool

Important: Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.

1. Lubricate the pinion bearings with axle lubricant.





2. Assemble the J45692-5 (2) and the outer pinion bearing onto the J21777-43 (1) as shown.





3. Install the J45692-5, the outer pinion bearing, and the J21777-43 into the axle housing.
4. Install the inner pinion bearing into the axle housing.





5. Install the J21777-35, 9.75 inch axle, or the J45692-3, 10.5 inch axle, into the inner pinion bearing as shown.





6. Install the J45692-1 into the axle housing as shown.
7. While holding the J21777-43 stationary, tighten the nut on the J21777-43 just until the end play between the pinion bearings is removed.
8. Rotate the assembly several times in both directions in order to seat the pinion bearings.
9. Measure the rotating torque of the assembly using an inch-pound torque wrench.

The rotating torque of the assembly should be between 2.3 - 5.1 Nm (20 - 45 inch lbs.).
10. If the rotating torque of the assembly is less than 2.3 Nm (20 inch lbs.), continue to tighten the nut of the J21777-43 until a rotating torque of 2.3 - 5.1 Nm (20 - 45 inch lbs.) is obtained.





11. Assemble the J45692-2 (1) and the J21777-1 (2) as shown.





12. Install the J45692-2 (1) and the J21777-1 (2) into the axle housing. Place the stem of the J21777-1 onto the bottom step of the J45692-1 for the 9.75 inch axle, the middle step for the 10.5 inch axle.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Corresponding letters are stamped on the bearing caps and axle housing. The bearing caps must be reassembled in the same position as removed.

13. Install the bearing caps and bearing cap bolts.

Tighten the bearing cap bolts to 109 Nm (80 ft. lbs.).
14. Rotate the J21777-1 within the J45692-2. The J21777-1 must rotate back and forth freely with the discs. If the J21777-1 does not rotate freely, disassemble the components, inspect for proper seating and/or mix-aligned components and re-assemble.
15. Install the J8001 to the J21777-1 as follows:
15.1. Loosely clamp the J8001 onto the stem on the J21777-1.
15.2. Place the contact pad of the J8001 onto the mounting post of the J21777-1.
15.3. With the contact pad of the J8001 touching the mounting post of the J21777-1, loosen the lock nut on the J8001 and push down on the J8001 until the needle the J8001 has turned 3/4 of a turn clockwise.
15.4. Tighten the clamp on the J8001 finger tight.





16. Move the plunger of the J21777-1 (1) back and forth on the bottom step, 9.75 inch axle, or the middle step, 10.5 inch axle, of the J45692-1 (2) until the needle of the J8001 indicates the greatest deflection.
The deflection is the point where the needle changes direction.
17. At the greatest point of deflection, move the indicator housing of the J8001 until the needle indicates ZERO.
18. Move the plunger of the J21777-1 back and forth again to verify the ZERO setting. Adjust the housing of the J8001 as necessary to set the needle to ZERO.





19. Rotate the plunger of the J21777-1 (1) away from the J45692-1 (2).
The value indicated is the amount of pinion shim thickness required for a nominal pinion setting.
20. In order to adjust the pinion shim thickness for the drive pinion that is to be installed, do the following:
20.1. Read the number on the button end of the pinion. If the number on the button end of the pinion is "0", no adjustment of the pinion preload shim pack is necessary.
20.2. If the number is not "0", the number will also have a corresponding "+" or "-" in front of it. The "+" or "-" indicates the amount of pinion preload shim thickness that either needs to be added to or subtracted from the amount determined in step 19 in order to the drive pinion gear to be positioned properly within the axle housing.
^ * For example, if the number on the button end of the pinion is a "+3", this indicates that 0.0762 mm (0.003 inch) of shim thickness will need to be subtracted from the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table.
^ If the number on the button end of the pinion is a "-3", this indicates that 0.0762 mm (0.003 inch) of shim thickness will need to be added to the value determined in step 19 in order to place the teeth of the pinion in the best running position with the teeth of the ring gear. Refer to the table.

21. Remove the pinion depth setting tools.
22. Remove the pinion bearings.
23. Install the pinion position shim onto the drive pinion.
Measure the thickness of the shim with a micrometer in order to verify the thickness.





24. Install the inner pinion bearing onto the drive pinion using the J24433.





25. Install the pinion bearing preload spacer (1) onto the drive pinion, 10.5 inch axle only.
26. Install the original pinion preload shims (2) onto the drive pinion. If the original shims are not available, assemble 1.52 mm (0.060 inch) of pinion preload shims to install.

Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.
27. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
28. Install the outer pinion bearing.
29. Install the thrust washer.
30. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
31. Install the washer.
32. Install the pinion yoke nut.

Tighten the pinion yoke nut to 252 Nm (186 ft. lbs.).
33. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

The rotating torque of the drive pinion should be between 2.3 - 5.1 Nm (20 - 45 inch lbs.).





34. If the rotating torque of the drive pinion is not within specifications, adjust the pinion preload shim thickness by doing the following:
34.1. Install the J8614-01 to the pinion yoke.
34.2. Remove the pinion nut while holding the J8614-01.
34.3. Remove the washer.
34.4. Install the J8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
34.5. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1).
34.6. Remove the thrust washer.
34.7. Install the J22536 Ensure that the J22536 is firmly seated on the drive pinion.
34.8. Drive the pinion out using the J22536 and a hammer.
34.9. Remove the outer pinion bearing.
34.10. Remove the pinion preload shim(s).
34.11. Adjust the amount of pinion preload shim thickness by doing the following:

Important: Removing approximately 0.0254 mm (0.001 inch) of shim thickness will increase the rotating torque by approximately 71-89 Nm (8-10 inch lbs.).

^ If the rotating torque is too low, remove the appropriate amount of shim thickness from the shim thickness pack using the guideline above.

Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.

Important: Adding approximately 0.0254 mm (0.001 inch) of shim thickness will decrease the rotating torque by approximately 71-89 Nm (8-10 inch lbs.).

^ If the rotating torque is too high, add the appropriate amount of shim thickness to the shim thickness pack using the guideline above.

Measure each shim separately with a micrometer and add the thickness together to determine the total shim pack size.

35. Install the new pinion preload shim pack onto the drive pinion.
36. Install the drive pinion with the inner pinion bearing and the pinion preload shims into the axle housing.
37. Install the outer pinion bearing.
38. Install the thrust washer.
39. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
40. Install the washer.
41. Install the pinion yoke nut.

Tighten the pinion yoke nut to 252 Nm (186 ft. lbs.).
42. Measure the rotating torque of the drive pinion using an inch-pound torque wrench.

The rotating torque of the drive pinion should be between 2.3 - 5.1 Nm (20 - 45 inch lbs.).
43. If the rotating torque of the drive pinion is not within specification, adjust the pinion bearing preload shim pack as necessary following the steps above.





44. If the rotating torque is within specifications, install the J8614-01 to the pinion yoke.
45. Remove the pinion nut while holding the J8614-01.
46. Remove the washer.





47. Install the J8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
48. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1).





49. Install the new pinion oil seal using the J45710.
50. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
51. Install the washer.
52. Install the new pinion yoke nut.

Tighten the pinion yoke nut to 339 Nm (250 ft. lbs.).
53. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. The rotating torque of the drive pinion should be between 2.3 - 5.1 Nm (20 - 45 inch lbs.).





Pinion Marking Table