Assembly of Differential Into Housing

RING GEAR AND PINION BACKLASH




1. Place differential assembly into housing. Differential master bearings should still be assembled to case. Install outboard spacers.




2. Set up dial indicator as shown. Be sure to locate dial indicator on a flat surface of one of the ring gear screws.

Force the differential case assembly (ring gear) away from the pinion gear. With force still applied to the differential case, set indicator at zero "0"

3. Force the differential case assembly (ring gear) into mesh with the pinion gear to obtain an indicator reading. Repeat until the same reading is obtained each time. This reading will be the necessary amount of shims required between the differential case and differential bearings on the ring gear side. Remove indicator and differential case from the carrier. Remove master bearings from differential case.




4. As determined in Step 3 place the required amount of shims on the ring gear hub of the differential case. For example: if the reading in Step 3 was 1.14mm (0.045 inch), place 1.14mm (0.045 inch) amount of shims on the hub of the ring gear side of the differential case.




5. Install the bearing cone on the ring gear side of the differential case. Drive the bearing onto the hub using Differential Side Bearing Replacer, D81 T-4221-A.

6. To determine the correct amount of shims to be placed on the hub of the drive pinion side of the differential case, subtract the reading obtained in Step 3 from the Total Differential Case Endplay. Total Case Endplay was determined under Steps 9 and 10 of Differential Case- Assembly. When this amount is determined, add 0.38mm (0.015 inch) to the amount for a Model 60, or 0.25 mm (0.010 in) for Models 70-80. This is the required amount of shims to be placed on the hub of the drive pinion side of the differential case.

For example: Total Differential Case Endplay on a Model 60 was 2.3O mm (0.091 inch). The reading in Step 3 was 1.14mm (0.045 inch), and when subtracted from 2.3O mm (0.091 inch) gives 1.1 6mm (0.046 inch). 0.36mm (0.015 inch) is added to give 1.52mm (0.061 inch) amount of shims to be placed on the hub of the drive pinion side of the differential case.

7. Place the required amount of shims on the hub of the drive pinion side of the differential case.

8. Install the bearing cone on the hub of the drive pinion side of the differential case. Place Step Plate 080L-830-7 for Model 60 axles and D8OL-630-8 on Model 70 and 80 axles on the ring gear side bearing to protect the bearing during installation of the drive pinion side bearing. Place the bearing on the drive pinion side hub and drive it on using Differential Side Bearing Replacer, D81T-4221-A.

9. Install spreader Tool-4000-E and indicator D78P-4201-B to carrier. Do not spread carrier over 0.38mm (0.015 inch). Remove indicator.




CAUTION: Do not spread carrier over 0.38mm (0.015 inch).