Differential Case and Pinion Set Up

Special Tools:

Differential Case End Play Check

1. Install the outboard spacers in the side from which they were removed.

2. Note: Remove all nicks, burrs, dirt, etc., from the differential case hubs, to allow the bearings to rotate freely.

Place the special tool on the differential case hubs, and position the assembly into the differential housing.
- For Model 60/70 axles, use tool 205-DO47.
- For Model 70HD/80 axles, use tool 205-DO48.

3. Note: Use a Dial Indicator with a minimum travel capability of 5.08 mm (0.200 inch).

Note: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Mount the special tools as shown. Locate the tip of the Clutch Housing Alignment Adapter on a flat surface of one of the bolts.

4. Note: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.

Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.

5. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

6. After making sure the reading is correct, remove the special tools and the differential from the differential housing. Do not remove the Master Bearings from the differential case at this time.