Ring Gear and Drive Pinion Set Up
1. Assemble and position Pinion Depth Gauge Set.
(1) Position Screw.
(2) Position Aligning Adapter.
(3) Position Gauge Disc.
(4) Position Gauge Block.
(5) Position the inner differential pinion bearing.
(6) Position the outer differential pinion bearing.
(7) Thread on Handle and tighten.
NOTE: Apply only a light oil film on the pinion bearings before performing this measurement.
2. Rotate the gauge block several half turns to ensure proper seating of the pinion bearings and position the gauge block.
NOTE: The gauge block must be offset to obtain an accurate reading.
3. Install Gauge Tube.
(1) Position the gauge tube and paper shipping tags.
(2) Install the differential side bearing caps.
(3) Install the four differential side bearing cap bolts
4. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
- The pinion bearing adjustment shim is checked between the gauge block and the gauge tube.
NOTE:
- Drive pinion bearing adjustment shims must be flat and clean.
- A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the gauge block and the gauge tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integrate rear axle assemblies.
5. Remove Pinion Depth Gauge Set from the axle housing.
6. Select the proper pinion bearing adjustment shim per the following chart.
- If a new gearset is used, notice the plus (+), minus (-), or zero (O) etching on both the original and the new drive pinion and adjust the thickness of the new selective shim according to the charts.
7. Use (A) press and (B) Pinion Bearing Cone Replacer to press the differential pinion bearing until it is firmly seated on the pinion and pinion
NOTE: The same pinion bearing used in this procedure must be used in the final axle assembly.
8. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
9. Install the front pinion seal.
(1) Install the front pinion bearing cone and roller.
(2) Install the oil slinger in the axle housing.
(3) Install the (A) pinion seal on the (B) Pinion Seal Replacer.
CAUTION: Installation without the proper tool may result in early seal failure. If the pinion seal becomes cocked during installation, remove it and install a new one.
10. Install the differential pinion; refer to Differential Ring and Pinion procedure.
11. Place the (A) differential case in the (B) housing.
12. Install a shim on the left side.
13. Install the (A) left bearing cap and loosely install the (B) bearing cap bolts.
NOTE:
- Triangles on bearing cups must point outboard.
- Apply pressure toward the left side to make sure the left bearing cup is seated.
14. Install progressively larger shims on the right side until the largest shim selected can be assembled with a slight drag feel.
15. Install the right side bearing cap and tighten the bolts.
16. Rotate the differential case to make sure it rotates freely.
17. Use Dial Indicator with Bracketry to measure ring gear backlash.
- Turn the ring gear without turning the pinion gear and record the measurement.
NOTE: Specifications shown are maximum backlash.
18. To increase backlash, install a (A) thicker shim and a (B) thinner shim as shown.
- If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
NOTE: The bearing caps must be removed before the shims can be installed.
19. To decrease backlash, install a (A) thicker shim and a (B) thinner shim as shown.
NOTE: The bearing caps must be removed before shims can be installed.
20. Rotate the differential several times to make sure the differential bearings are set properly.
21. Use Dial Indicator with Bracketry to recheck the backlash.
NOTE: Specifications shown are maximum backlash.
22. Remove the (A) bearing cap bolts and (B) bearing caps.
23. Make sure shims are fully seated and differential turns freely.
- Use (A) Shim Driver to install shims.
NOTE: To establish differential bearing preload, increase both left and right shim sizes as shown.
24. Install the bearing caps and bearing cap bolts.
25. Use Dial Indicator with Bracketry to recheck the backlash.
NOTE: Specifications shown are maximum backlash.
26. Install the axle shafts.