4 - Pinion

Fig. 5 Drive pinion & bearing shim adjustment:

1. Install front pinion bearing cup in carrier using tool J-7817 or equivalent.
2. Install spacer (E) into carrier bore, Fig. 5.
3. Slide rear pinion bearing and cap (F) onto thru bolt (D) and rear bearing into axle housing.
4. Install thru bolt (D), rear bearing and cap (F) into axle housing.
5. Assemble front bearing cone (A) and spacer (B) onto thru bolt.
6. Rotate nut and shaft while increasing torque on nut until a rotational torque of 15-22 inch lbs. is obtained. Rotate thru bolt back and forth when tightening nut to properly seat bearing.
7. Install discs on thru bolt assembly as shown in Fig. 5. Position carrier so dial indicator contact rod is directly over gauging area of gauge plate J-35118-2. Discs must be fully seated in side bearing bores.
8. Install bearing caps over gauge shaft discs, then the cap attaching bolts. torque attaching bolts to 40 ft. lbs.
9. With dial indicator rod contacting gauging area of J-35118-2, rock gauge shaft back and forth until dial indicator measures the greatest deflection, then zero dial indicator.
10. Rotate gauge shaft until shaft does not contact gauge plate, then note measurement.
11. Select correct pinion shim as follows:
a. If reusing production pinion, and pinion is marked with a ``+,'' correct shim will have a thickness equal to gauge reading minus amount specified on pinion.
b. If reusing production pinion, and pinion is marked with a `` - ,'' correct shim will have a thickness equal to gauge reading plus amount specified on pinion.
c. If using a production or service pinion which has no marking, correct shim will have a thickness equal to gauge reading.
12. Install selected pinion shim into carrier, then press rear pinion bearing cup into carrier using tool J-5590 or equivalent.
13. Press rear pinion bearing onto pinion using a bearing installation tool, then install pinion in carrier.
14. Install collapsible spacer and front bearing onto pinion while supporting pinion under head.
15. Install oil seal, companion flange and new nut on pinion, then tighten pinion nut until a rotating torque of 10-25 inch lbs. with new bearings or 5-12 inch lbs. with original bearings is obtained while rotating pinion forwards to seat bearings.
16. If preload is excessive after tightening pinion nut, replace collapsible spacer and repeat steps 14 and 15.