Differential Case Installation
Differential Bearing Installation:
1. Install differential bearings on the case hubs using Differential Side Bearing Replacer, T57L-4221-A2 or equivalent.
NOTE: Press against the bearing cone only.
Differential Bearing Installation:
2. Press on the NEW excitor ring and ring gear if removed onto the differential case. Refer to procedure in this Section. Apply Stud and Bearing Mount EOAZ-19554-BA (ESE-M4G167-A2) or equivalent to ring gear bolts and install. Tighten the bolts to 95-115 Nm (70-85 ft-lbs).
Differential Subassembly Installation:
3. With pinion depth set and pinion installed, place differential case subassembly (with ring gear, excitor ring, thrust washers, side gears, bearings and cups) in carrier.
Shim Installation:
4. Install a 0.265 inch shim on left side.
Bearing Cap Installation:
5. Install left bearing cap and tighten bolts finger tight.
Differential Shimming:
6. Install progressively larger shims on the right side until the largest shim selected can be assembled with a slight drag feel.
NOTE: Apply pressure towards left side to insure that the left bearing cup is seated.
Shim Installing:
7. Install the rest of the shims by driving into position with Shim Driver. T85L-4067-AH.
Torquing Bearing Cap Bolts:
8. Install right side bearing cap and tighten bearing cap bolts to 95-115 Nm (70-85 ft-lbs).
Check Differential To Insure A Free Rotation:
9. Rotate assembly to insure free rotation.
Checking Ring Gear For Backlash:
10. Check ring gear and pinion backlash. If the backlash is 0.008 inch to 0.015 inch (0.012 inch to 0.015 inch preferred) proceed to Step 32. If the backlash is zero, go to Step 26. If the backlash is not zero, but is less than 0.008 inch, or more than 0.015 inch, then go to Step 28.
Differential Shim Adjustment:
11. If a zero backlash condition occurs, add 0.020 inch to the right side and subtract 0.020 inch from the left side to allow for a backlash reading.
Checking Ring Gear For Backlash:
12. Recheck backlash. See Step 28, if backlash is not within specification. Backlash specification: 0.008 inch to 0.015 inch. Preferred range: 0.012 inch to 0.015 inch.
If backlash is within specification, go to Step 29.
Backlash Chart:
General Backlash Adjustment Rules:
13. If backlash is not to specification, correct backlash by increasing thickness of one shim and decreasing thickness of the other shim by the same amount. Refer to chart for approximate shim change.
Torquing Bearing Cap Bolts:
14. Install shim and bearing caps. Tighten cap bolts to 95-115 Nm (70-85 ft-lbs).
Rotate Differential To Insure Bearing Seating:
15. Rotate assembly several times to insure proper seating of differential bearings.
Checking Ring Gear For Backlash:
16. Recheck backlash. If backlash is within specification, go to Step 32. If backlash is not within specification, repeat Step 28.
Backlash Specification: 0.008 inch to 0.015 inch. Preferred range: 0.012 inch to 0.015 inch.
Backlash Adjustment:
17. Remove bearing caps and bolts. To establish differential bearing preload, increase both left and right shim sizes by 0.006 inch. Make sure shims are fully seated and assembly turns freely.
Torquing Bearing Cap Bolts:
18. Install bearing caps and tighten cap bolts to 95-115 Nm (70-85 ft-lbs). Recheck backlash. If not to specification, repeat Step 28.
19. Utilize white marking compound to obtain a tooth mesh contact pattern in your assembly. Pattern legibility can be improved by connecting the driveshaft and rotating both tires in drive and coast direction.
Reincorporation of pattern inspection is intended to allow technician the ability to detect gross errors in set-up prior to complete reassembly. Pattern contact should be within the primary area of the ring gear tooth surface avoiding any "narrow" or "hard" contact with outer perimeter of tooth (top to root, toe to heel). Pattern inspection should be on the drive (pull) side. Assembly with correct drive pattern will result in satisfactory coast performance. If gross pattern error is detected, with preferred backlash (0.012 inch-0.015 inch), recheck pinion shim selection.