9.5 Inch Axle
Locking Differential Adjustment (9.5 Inch Axle)^ Tools Required
- J 7872 Magnetic Base Dial Indicator
- J 8001 Dial Indicator Set
Adjustment of the Differential
Important: If it is necessary to replace the left side gear cam unit and disc assembly, the right side gear and disc assembly, or the thrust block, the entire differential must be adjusted. The differential is adjusted using selective thickness thrust washers between the clutch disc assemblies and the case and/or different selective thickness thrust blocks.
When adjusting the differential, note the following:
^ Build up the clutch disc assemblies properly.Proper clearance between parts is critical to the operation of the unit.
^ Adjust the backlash and thrust block clearance in the following order:
1. The left side gear backlash
2. The right side gear backlash
3. The thrust block clearance
Left Side Gear Backlash Adjustment
1. Install the new left side thrust washer into the flange-end of the differential case.
2. Install the left side locking differential side gear cam unit and clutch disc assembly into the differential case.
3. Install the differential pinion gears with the deferential pinion gear thrust washers into the differential case.Align the openings of the differential pinion gears and the differential pinion gear thrust washers to the pinion shaft opening in the differential case.
4. Install the pinion shaft. It may be necessary to press down on the side gear in order to align the pinion gear shaft opening with the pinion shaft opening in the differential case. If the pinion shaft cannot be installed after pressing on the side gear, replace the locking differential clutch disc thrust washer with a thinner washer.
5. Install the pinion shaft lock bolt.
Tighten the pinion shaft lock bolt finger tight.
Notice:
Refer to Fastener Notice in Service Precautions.
6. Rotate the pinion gear closest to the lock bolt so that one of the teeth is pointing downward, perpendicular to the ring gear flange.
7. Install a brass drift between the side gear and the pinion shaft. Press the brass drift in far enough in order to compress the clutch discs.
8. Measure the backlash of the pinion gear and the side gear by doing the following:
1. Install the J 7872 (1) to the ring gear flange.
2. Loosely clamp the J 8001-3 (2) onto the stem on the J 7872 (1).
3. Place the contact pad of the J 8001-3 on one of the teeth of the pinion gear closest to the pinion shaft lock bolt.Turn the dial of the J 8001-3 until the needle and the dial face indicate ZERO.
4. Tighten the lock nut of the J 8001-3 finger tight.
5. Pull the pinion gear firmly into the differential case seat.
6. Rotate the pinion gear back and forth.
7. Measure the backlash.
The backlash between the differential pinion gears and the locking differential side gear cam unit should be 0.279-0.432 mm (0.011-0.017 inch).
9. If the backlash is too large, install a thicker locking differential clutch disc thrust washer and recheck the backlash.
10. If the backlash is too small, install a thinner locking deferential clutch disc thrust washer and recheck the backlash.
Locking differential clutch disc thrust washers are available in the following sizes:
^ 0.559 mm (0.022 inch)
^ 0.686 mm (0.027 inch)
^ 0.813 mm (0.032 inch)
^ 0.914 mm (0.036 inch)
^ 1.016 mm (0.040 inch)
^ 1.118 mm (0.044 inch)
^ 1.219 mm (0.048 inch)
^ 1.321 mm (0.052 inch)
Right Side Gear Backlash Adjustment
1. If necessary, remove the following from the differential case:
1. The pinion lock shaft bolt
2. The pinion shaft
3. The differential pinion gears
4. The differential pinion gear thrust washers
5. The locking differential side gear cam unit and clutch disc assembly
2. Install the right side differential side gear shim into the bell-end of the differential case.
3. Install the clutch disc assembly into the differential case.
4. Install the locking differential side gear.
5. Install the differential pinion gears with the differential pinion thrust washers into the differential case. Align the openings of the differential pinion gears and the differential pinion thrust washer to the pinion shaft opening in the differential case.
6. Press down on the locking differential side gear and install the pinion shaft.If the side gear cannot be pressed down far enough to install the pinion shaft, replace the differential side gear shim with a thinner shim.
7. Install the pinion shaft lock bolt.
Tighten the pinion shaft lock bolt finger tight.
8. Rotate the differential pinion gear so that one of the teeth is pointing downward, perpendicular to the ring gear flange.
9. Install a brass drift between the differential side gear and the pinion shaft. Press the brass drift in enough in order to compress the clutch discs.
10. Measure the backlash of the differential pinion gear and the locking differential side gear by doing the following:
1. Install the J 7872 (1) to the ring gear flange.
2. Loosely clamp the J 8001-3 (2) onto the stem on the J 7872 (1).
3. Place the contact pad of the J 8001-3 on one of the teeth of the pinion gear closest to the pinion shaft lock bolt. Turn the dial of the J 8001-3 until the needle and the dial face indicate ZERO.
4. Tighten the lock nut of the J 8001-3 finger tight.
5. Pull the pinion gear firmly into the differential case seat.
6. Rotate the pinion gear back and forth.
7. Measure the backlash.
The backlash between the differential pinion gear and the locking differential side gear should be 0.051-0.203 mm (0.002-0.008 inch).
11. If the backlash is too large, install a thicker locking differential clutch disc thrust washer and recheck the backlash.
12. If the backlash is too small, install a thinner locking differential clutch disc thrust washer and recheck the backlash.
Differential side gear shims are available in the following sizes:
^ 0.254 mm (0.010 inch)
^ 0.381 mm (0.015 inch)
^ 0.508 mm (0.020 inch)
^ 0.635 mm (0.025 inch)
^ 0.762 mm (0.030 inch)
^ 0.899 mm (0.035 inch)
^ 1.016 mm (0.040 inch)
^ 1.143 mm (0.045 inch)
^ 1.270 mm (0.050 inch)
^ 1.397 mm (0.055 inch)
^ 1.524 mm (0.060 inch)
Thrust Block Clearance Adjustment
1. Install the locking differential side gear thrust washer into the differential case.
Important:
The left and right side gear backlash measurements must be done before the thrust block measurement can be completed.
2. Install the left side locking differential side gear cam unit and clutch disc assembly into the differential case.
3. Install the right side differential side gear shim into the differential case.
4. Install the right side locking differential side gear and clutch disc assembly into the differential case.
5. Install the pinion shaft.
6. Install the pinion shaft bolt.
^ Tighten the pinion shaft bolt finger tight.
7. Install a brass drift between the left side gear and the pinion shaft. Press the brass drift in far enough in order to compress the clutch disc assembly and hold the left side gear assembly in place.
8. Install a brass drift between the right side gear and the pinion shaft. Press the brass drift in far enough in order to hold the right side gear assembly in place.
9. Measure the distance between the side gear faces using a 25.4-50.8 mm (1-2 inch) telescoping gage.
Important:
Do not measure the distance between the side gear teeth.
10. Remove the telescoping gage.
11. Measure the telescoping gage with a micrometer. Record the measurement.
12. Compare the measurement obtained in step 11 to the thrust block sizes available. If the measurement is equal to one of the thrust blocks sizes available, then select that thrust block.
13. If the measurement obtained in step 11 is not equal to one of the thrust blocks sizes available, then select the thrust block that is smaller than the measurement. For example, if the measurement is 40.869 mm (1.609 inch), select the 40.792 mm (1.606 inch) thrust block.
14. If the measurement obtained in step 11 is less than 40.488 mm (1.594 inch), then reduce the left side gear thrust washer or the right side gear shim thickness in order to increase the thrust block opening.
Important:
The backlash must be rechecked and adjusted to specification anytime the left and/or the right thrust washers are replaced.
15. If the measurement obtained in step 11 is greater than 41.120 mm (1.622 inch), then increase the left side gear thrust washer or the right side gear shim thickness in order to decrease the thrust block opening.
16. Recheck the left and/or right side gear backlash and adjust as necessary.
17. Recheck the thrust block clearance and adjust as necessary.