Final Assembly-Differential Into Housing
1. Assemble differential bearing cups to differential bearing cones. Install differential assembly into carrier.
Use a rawhide hammer to seat differential assembly into crossbore of carrier. Care should be taken to avoid nicking the teeth of the ring gear and pinion during assembly. Remove the spreader from the carrier.
2. Install bearing caps. Make sure the letters stamped on the caps correspond with those on the carriers. Tighten bearing cap screws to 108- 122 Nm (80-90 ft-lbs).
3. Check ring gear and pinion backlash in three equally spaced points with dial indicator.
Backlash tolerance is 0.13-0.203mm (0.005-0.008 inch) and cannot vary more than 0.05mm (0.002 inch) between points checked.
High backlash is corrected by moving the ring gear closer to the pinion.
Low backlash is corrected by moving ring gear away from the pinion.
These corrections are made by switching shims from one side of the differential case to the other.
4. To confirm total preload, recheck torque to rotate with an inch-pound wrench as shown. The reading should be higher than the initial reading (taken without the differential case installed) by the following amount if new bearings have been installed as recommended:
3.54 & 3.73 ratios 7-9 in-lbs.
4.10 & 4.56 ratios 6-8 in-lbs.
4.63 & 5.13 ratios 6-8 in-lbs.
If total preload is too high, remove an equal amount of shims from each differential case hub.
If total preload is too low, add an equal amount of shims to each differential case hub.
Ring Gear & Pinion Tooth Pattern Interpretation
5. The final pinion position will be verified by using the GEAR CONTACT PATTERN METHOD.
6. The TOE of the gear tooth is the portion of the tooth surface at the end towards the center. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of the gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. The illustrations show typical patterns only, and explains how patterns shift as gear location is changed. When making pinion position changes, shims should be changed in the range of 0.05mm (0.002 inch)0 to 0.10mm (0.004 inch) until correct pattern has been obtained.
When a change in backlash is required, backlash shims should be changed in the range of 1-1/2 times the amount of backlash required to bring the gears into specification. For example, if the backlash needed to be changed by 0.10mm (0.004 inch), the shim pack should be changed by 0.1 5mm (0.006 inch) as a starting point. The actual amount of backlash change obtained will vary depending upon the ratio and gear size.
High backlash is corrected by moving the ring gear closer to the pinion. Low backlash is corrected by moving the ring gear away from the pinion. These corrections are made by switching shims from one side of the differential case to the other.
NOTE: When making changes, note that two variables are involved. Example: If you have the backlash set correctly to specifications and you change the pinion position shim, you may have to readjust the backlash to the correct specification before checking the pattern. Refer to pattern interpretation.
WARNING: GEAR TEETH MAY HAVE SHARP EDGES. WHEN HANDLING GEARS, USE CARE TO AVOID PERSONAL INJURY.
a. Paint ring gear teeth with a marking compound to both the drive and coast side.
b. Rotate ring gear one complete revolution in both directions while load is being applied with a large screwdriver or similar tool between the carrier casting and differential case flange.
Pattern Movements Summarized
a. Decreasing backlash moves the ring gear closer to the pinion.
Drive pattern (convex side of gear) moves slightly lower and toward the toe.
Coast pattern (concave side of gear) moves lower and toward the toe.
b. Increasing backlash moves the ring gear away from the pinion.
Drive pattern moves slightly higher and toward the heel.
Coast pattern moves higher and towards the heel.
c. Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear.
Drive pattern moves deeper on the tooth (flank contact) and slightly toward the toe.
Coast pattern moves deeper on the tooth and toward the heel.
d. Thinner pinion position shim with the backlash constant moves the pinion further from the ring gear.
Drive pattern moves toward the top of the tooth (face contact) and toward the heel.
Coast pattern moves toward the top of the tooth and slightly toward the toe.
7. Install new cover gasket and install cover plate. Tighten screws to 41-54 Nm (30-40 ft-lbs.).
Figure shows the flat mounting surface cover plate on Dana design axles. This cover plate requires the use of a silicone rubber sealer material, Silicone Rubber E7TZ-19562-A (ESL-M4G273-A), or equivalent rather than a gasket.
The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material.
CAUTION: Clean both flat surfaces with a suitable solvent to remove all traces of oil film.
Sealant material must meet specifications of ESLM4G273-A, ASTM1, GE503, Z1, Z2 and Z3 sealant or equivalent.
8. Apply Silicone Rubber E7TZ-19562-A (ESLM4G273-A) or equivalent to cover plate surface. Ensure that the sealer bead is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.
The bead is to be 3.18-6.35mm (1/8 inch to 1/4 inch) wide.
NOTE: Cover assembly must be installed within 15 minutes of application of the silicone or new sealant must be applied.
Assemble two cover screws into cover at 8 0'clock and 2 0'clock position. Use these two holes to guide cover plate into position on the carrier.
Install remaining screws. Tighten alternately and evenly. Tighten screws to 41-54 Nm (30-40 ft-lbs.).
ALLOW ONE HOUR CURE TIME BEFORE FILLING CARRIER WITH THE PROPER AMOUNT OF SPECIFIED LUBRICANT.
9. Install axle shafts as outlined under axle shaft removal in Wheel Hubs and Bearings-Rear DANA Full Floating Axle.
10. Fill axle housing with specified amount of Rear Axle Lubricant, C6AZ-19580-E (ESW-M2C105-A) rear axle lubricant.