Rear Axle - 210RII

ADJUSTMENT - PINION DEPTH MEASUREMENT PINION DEPTH VARIANCE





Ring gear and pinion are supplied as matched sets. Identifying numbers for the ring gear and pinion are etched into the pinion gear face. A plus (+) number, minus (-) number or zero (0) along with the gear set sequence number (01 to 99) is on each gear. The pinion depth variance (1) is the amount the depth varies from the standard depth setting of a pinion marked with a zero. The remaining numbers are the sequence number of the gear set. The standard depth provides the best gear tooth contact pattern.

Pinion Depth Shim And Collapsible Washer:

Compensation for pinion depth variance is achieved with select shims. The shims (3) are sandwiched between the pinion head bearing cup and axle housing.

If installing a new gear, note the depth variance number of the original and replacement pinion. Add or subtract this number from the original depth shim to compensate for the difference in the depth variances. The numbers represent deviation from the standard in microns. If the number is negative, add that value to the required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth shim.

Pinion Gear Depth Variance:

PINION GEAR DEPTH VARIANCE

PINION DEPTH MEASUREMENT
Pinion depth measurement is taken with the pinion head and tail bearing cups pressed into the axle housing without the shim.





1. Press pinion head bearing cup into housing using Tools C-4171 (1) and C-4310 (2).





2. Press pinion tail bearing cup into housing using Tools C-4171 (1) and D-146 (2).





3. Install Pinion Height Block 6739 (3), Pinion Gage Block 9085 (2), and pinion head bearing cone (1) onto Screw 6741. Install assembly into axle housing and through bearing cups.





4. Install pinion tail bearing and Cone 6740 (4). Tighten Cone 6740 by hand until 3.4 Nm (30 inch lbs.) of rotating torque is measured at Screw 6741 (5).





5. Install Arbor Discs 9083 (1).





6. Install Arbor Bar D-115-3 (1).





7. Verify pinion depth setup is a shown.





8. Install Dial Indicator 9524 (1) to Scooter Block D-115-2A (2). Secure with set-screw (3).





9. Install Indicator/Block assembly to top of Height Block 6739 (1). Zero indicator on top surface.





10. Slide indicator probe off of height block and onto Arbor Bar D-115-3 (2). As indicator contacts Arbor Bar (2), indicator needle will rotate clockwise. Continue moving indicator probe to the crest of the arbor bar and record the highest reading.





11. Select a shim equal to the dial indicator reading plus the drive pinion gear depth variance number etched into the pinion face (1). For example, if the depth variance is -01, subtract 0.01 mm (0.0004 inch) from dial indicator reading.





12. Using Tool C-4171 (2) and Remover 9084 (1), drive out pinion head bearing cup and insert specified shim.

ADJUSTMENT - SIDE BEARING PRELOAD AND RING GEAR BACKLASH
DIFFERENTIAL SIDE BEARING PRELOAD MEASUREMENT/CORRECTION
Differential side bearing preload should be measured and adjusted after the following scenarios:
^ Differential case replacement
^ Differential side bearing replacement
^ Axle housing replacement
^ Loss or replacement of side bearing snap rings
If none of these situations apply, refer to Adjustment - Ring Gear Backlash





1. Install Spreader Adapter Plates 9226 (1).





2. Mount axle housing to Spreader W-129-B (1).





3. Set up Dial Indicator Set C-3339-A as shown to measure axle housing spread:
a. Clamp SP-5426 (1)
b. Post SP-5425-B (2)
c. Metric Dial Indicator 9524 (3)





4. If differential side bearing cups and snap rings are already removed at this point, skip to Step 8. Otherwise, expand spreader (1) to spread axle housing no more than 0.30 mm (0.012 inch).





5. Remove both differential side bearing snap rings (1). Tag snap ring to ensure replacement to original position.





6. Measure and record snap ring (2) thickness for later use.





7. Relax spreader (1) to relieve tension on axle housing.





8. Install right (pinion) side bearing cup and snap ring.





9. Zero dial indicator.
10. Expand spreader (1) to spread axle housing no more than 0.30 mm (0.012 inch).





11. Install left (ring gear) side bearing cup and snap ring (1).





12. Relax spreader (1) to relieve tension on axle housing.





13. Measurement showing on indicator (3) is the axle housing retained spread. Proper differential side bearing preload is achieved with an axle housing retained spread of 0.11 - 0.17 mm (0.004 - 0.007 inch).
14. If retained spread is less than 0.11 mm (0.004 inch), increase snap ring thickness at each side in equal increments.
15. If retained spread is greater than 0.17 mm (0.007 inch), decrease snap ring thickness at each side in equal increments.

RING GEAR BACKLASH MEASUREMENT/CORRECTION
Differential Ring Gear Backlash should be measured and adjusted after the following scenarios:
1. Ring and pinion gear replacement
2. Pinion head bearing replacement
3. Pinion depth (shim) adjustment
4. Differential case replacement
5. Differential side bearing replacement
6. Axle housing replacement





NOTE: If Spreader W-129-B is installed, make sure tension on axle housing is relieved.

7. Set up Dial Indicator Set C-3339-A as shown to measure ring gear backlash:
a. Clamp SP-5426 (1)
b. Post SP-5425-B (2)
c. Metric Dial Indicator 9524 (3)
8. Rotate ring gear one direction to take up clearance to pinion. Verify indicator tip is in contact with ring gear and zero indicator. Rotate ring gear back and forth and record measurement. Ring gear backlash should be 0.10 - 0.16 mm (0.004 - 0.006 inch). Verify back lash measurement in four (4) positions.





9. If backlash measurement is less than 0.10 mm (0.004 inch), it is necessary to decrease the snap ring thickness on the ring gear (left) side, and increase the thickness on the pinion (right) side.
10. If backlash measurement is greater than 0.16 mm (0.006 inch), it is necessary to increase the snap ring thickness on the ring gear (right) side, and decrease the thickness on the pinion (left) side.

GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.
1. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth.
2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern.
3. With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.

Gear Tooth Contact Patterns:

The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash as necessary