Assembly

1. Place differential case in vise. Apply grease, Long Life Lubricant, C1AZ-19590-BA or equivalent, to new side gear thrust washers and to hubs and thrust face of the new side gears. Install both side gears. Apply grease to the new pinion mate spherical washers and the new pinion mate gears.

2. Assemble both side gears and thrust washers, hold in place with hand, then assemble the pinion mate gears and washers to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated with Rear Axle Lubricant C6AZ-19580-E before assembly.




3. Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case. If the gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shaft.

4. Use a drift to line up the holes with those of the differential case.




5. Assemble pinion mate shaft, drive on shaft to remove drift. Be sure lock pin hole of the shaft is lined up with the lock pin hole of the case.




6. Assemble lock pin. Peen metal of case over pin in two places 18O° apart to lock in place. Note the location of the slot in the lockpin and peen 900 away.

NOTE: The semi-float shaft riding bearing design uses a lock pin that is assembled with the use of a 12 point socket wrench. Use a new lock pin and assemble finger tight only. This procedure is necessary to prevent differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. A new lock pin should be installed after assembling the axle shafts.

7. Be sure flange face of the case is free of nicks or burrs. Assemble ring gear to case. Line up holes of the ring gear with those of the case. Use new ring gear bolts. Draw up gear bolts alternately and evenly. Tighten ring gear bolts to 136-163 Nm (100-120 ft-lbs) for grade 8 bolts. Tighten grade 9 bolts 169-183 Nm (125- 135 ft-lbs) for Model 60, 61,70 axes. Tighten Model 80 ring gear bolts to 285-312 Nm (210- 230 ft-lbs).

8. Install Master Differential Bearings, Tool D81 T-4222-D for Model 60 and 70-2U axles. Use Tool D81T-4222-E for 70-HD and Model 80 axles onto the differential case. Remove all nicks, burrs, dirt, etc., from hubs to allow bearings to rotate freely.




9. Assemble differential case into carrier (less pinion). Mount dial indicator with a magnetic base Tool D78P-4201-B as shown. Locate tip of indicator on flat surface of one of the ring gear screw spot faces. Force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero (0).

NOTE: Dial indicator should have a minimum travel of 5.O8mm (0.200 inch).




10. Force the differential assembly as far as it will go in the opposite direction. Repeat these steps until you have obtained the same reading. Record the reading of the indicator. This will be the total amount of shims required (less preload) and will be calculated later during assembly. After making sure the readings are correct, remove indicator and differential assembly from housing. DO NOT REMOVE MASTER BEARINGS FROM DIFFERENTIAL CASE AT THIS TIME.

This reading is the Total Differential Case Endplay which will be needed in Step 6 of Assembly of Differential into Housing later in this Section.




11. Ring gears and pinions are supplied in matched sets only. Matching numbers on both the pinion and ring gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion and ring gear before proceeding with assembly. The end of the pinion with the etched figures shown is known as the "button" end. The surface with the etched figures may or may not be a precision ground surface, which is necessary for use of the final chock gauge block with the pinion. If the surface is not precision ground, the tooth combination information stamped on the pinion stem between the bearing diameters will have the letter "B" following. Examples: 46-13B, 41-11B, and 41-10B are not finish ground and may not utilize the final check gauge block.




The distance from the centerline of the ring gear to the button end of the pinion for the Models 60-1 U, is 79.37mm (3.125) inch. For Model 70 and 80, the distance is 88.9mm (3.50 inch).

On the button end of each pinion, there is etched a plus + number, a minus - number, or a zero 0 number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the inner pinion bearing cup (the backface).

The difference from the centerline of the ring gear to the backface of the pinion for Model 60-1U is 127 mm (5.000 inch) for Model 70-2U, the distance is 136 mm (5.375 inch) and for Model 80 is 148 mm (5.812 inch).

For example-If a pinion is etched a plus m+8 (+3), this pinion would require 0.08mm (0.003 inch) less shims than a pinion etched 0. This means by removing shims, the mounting distance of the pinion is increased to 98.45mm (3.128 inch), which is just what a m+8 (+3) indicates. Or if a pinion is etched m-8 (-3), we would want to add 0.O8mm (0.003 inch) more shims than would be required if the pinion were etched 0. By adding 0.O8mm (0.003 inch) shims, the mounting distance of the pinion was decreased to 98.29mm (3.122 inch) which is just what a m-8 (-3) indicated.

If the old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to this same dimension. If a baffle is used in the axle assembly, it is considered as part of the shim pack.

To change the pinion adjustment, shims are available in thicknesses of mm 0.08, 0.13, and 0.25 (0.003 inch, 0.005 inch, and 0.010 inch).

NOTE: If baffle or slinger is bent or mutilated, it should be replaced.

Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original build up.

If a new gear set is being used, notice the (+) or (-) etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures.

For example-If the old pinion reads m+5 (+2) and the new pinion is m-5 (-2), add 0.10mm (0.004 inch) shims to the original shim pack.




SHIM SELECTION CHART - INCHES




SHIM SELECTION CHART - METRIC