Assembly to Carrier
Assembly to Carrier
Pinion and Ring Gear Backlash
1. Assemble ring gear to differential case. Use new bolts and tighten alternately and evenly to 95-122 Nm (70-90 lb-ft).
2. Place the differential case into position in the carrier. Dummy Bearings T86T-4222-AH should still be installed.
3. Force the differential case away from the drive pinion gear until it is completely seated against the cross bore face of the carrier.
4. Position a dial indicator so the indicator tip rests on a ring gear bolt head, or a flat machined surface. Zero the dial indicator.
5. Force ring gear against pinion gear. Rock ring gear slightly to make sure gear teeth are in contact.
6. Force ring gear away from drive pinion gear, making sure the dial indicator returns to zero.
7. NOTE: Repeat this procedure, until the dial indicator reading is the same. This reading should be recorded on the worksheet as Measurement "B."
Measure master differential bearing (tool) width. Use A or B depending on width.
Worksheet for Calculating Ring Gear Backlash and Differential Bearing Preload Shims
EXAMPLE A
1. Total amount of space measured without gearset assembled into carrier (Housing). Measurement A
2. Total amount of space measured with gearset assembled into carrier (Housing). Measurement B
ADJUSTMENTS:
3. Measurement A less .20mm (.008 inch) = C
4. Measurement B less .10mm (.004 inch) = D
5. C - D = E
After measurements and calculations have been made, assemble the shim packs using the figures determined in D and E and adjusting the pack as described.
RING GEAR SIDE:
D - .13mm (.005 inch) = Total shim pack thickness.
OPPOSITE SIDE:
E + .25mm (.010 inch) = Total shim pack thickness.
Assemble shim packs onto differential case hubs and assemble new differential bearing cones. Continue to build the axle assembly as described.
Worksheet for Calculating Ring Gear Backlash and Differential Bearing Preload Shims
EXAMPLE B
1. Total amount of space measured without gearset assembled into carrier (Housing). Measurement A
2. Total amount of space measured with gearset assembled into carrier (Housing). Measurement B
3. Measurement A minus Measurement B = Measurement C
After the measurements and calculations have been made, assemble the shim packs using figures determined in A, B and C and adjusting the pack as described below.
RING GEAR SIDE:
B - .13mm (.005 inch) = Total shim pack thickness.
OPPOSITE SIDE:
C + .25mm (.010 inch) = Total shim pack thickness.
Assemble shim packs onto differential case hubs and assemble new differential bearing cones. Continue to build the axle assembly as described.
4. NOTE: The Dana Model 35 axle controls differential bearing preload by placing the shims between the differential case and the differential bearing cone.
Remove the differential case from the carrier and remove the dummy bearings from the case.
5. As determined in Steps 5 through 7, place the required amount of shims on the ring gear side and opposite side of the differential case.
6. Drive the differential bearing onto the hub of the drive pinion side of the differential case using Driver Handle T80T-4000-W and Differential Bearing Replacer T85M-4221-A.
7. Install bearing cone on the pinion side of the differential case with Differential Bearing Replacer T85M-4221-A. Place the Pinion Bearing Cone Replacer T53T-4621-C on the ring gear bearing to prevent damage.
8. Install the differential bearing cups on the bearing cones.
9. Place Differential Housing Spreader TOOL-4000-E or equivalent on the case, using Housing Spreading Adapter Set T95T-4000-A and suitable spacers. Install Dial Indicator TOOL-4201-C or equivalent on the carrier housing. Do not spread the housing more than 0.25mm (0.010 inch).
10. NOTE: Be careful to not nick the teeth of the ring gear or pinion.
Install the differential case in the carrier. If necessary, use a rawhide or plastic hammer to seat the differential case into the carrier housing cross bore.
11. With partial and non-hunting/partial ring gear and pinion sets, align the marks on the ring gear and drive pinion if applicable. Some gearsets do not have marks, depending upon ratio.
12. Remove the spreader and dial indicator from the case.
13. NOTE: The matched numbers or letters stamped on the cap and carrier must correspond in both position and direction upon assembly.
Install bearing caps and bolts. Tighten bolts to 64-91 Nm (47-67 lb-ft).
14. NOTE: Backlash tolerance is 0.13-0.20mm (0.005-0.008 inch) and cannot vary more than 0.05mm (0.002 inch) between the three points.
NOTE: If backlash is high, the ring gear must be moved closer to the pinion by increasing the amount of shims on ring gear side and decreasing the amount of shims on the opposite side.
NOTE: If backlash is low, the ring gear must be moved away from the pinion by decreasing the amount of shims and increasing the amount of shims on the opposite side by an equal amount.
Install the dial indicator on the case. Check ring gear and pinion backlash at three equally spaced points on the ring gear.