Differential Assembly: Adjustments

Inner Axle Shaft Shim Adjustment

^ Tools Required
- J 34672 Depth Micrometer
- J 8001 Dial Indicator Set

The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced:
^ The inner axle shaft
^ The inner axle shaft housing
^ The output shaft
^ The differential carrier case
^ The ring and pinion gears
^ The differential case assembly
^ The differential bearings
^ The carrier connector





Front drive axle clutch shims are available in the following sizes:

1. Install the inner axle bearing and the inner axle seal, if necessary.





2. Install the following components into the inner axle shaft housing, 8.25 inch axle:
1. Install the inner axle shaft (1) into the front drive axle housing (4).
2. Install the thrust washer (5).
3. Install the retaining ring (7) into the front drive axle clutch gear (6).
4. Install the front drive axle clutch gear (6) onto the inner axle shaft (1). Drive the front drive axle clutch gear (6) into place with a plastic hammer.





3. Install the following components into the inner axle shaft housing, 9.25 inch axle:
1. Install the inner axle shaft (1) into the front drive axle housing (4).
2. Install the thrust washers (5, 6).
3. Install the retaining ring (7) into the inner axle shaft (1).

4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.

Important:
In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.






5. Using the J 34672, measure the distance from the edge of the front drive axle clutch gear to the machined flange surface of the inner axle housing.





6. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
7. Subtract the measurement obtained in step 6 from the measurement obtained in step 7.
8. The correct shim size will be one size smaller than the figure obtained in the previous step.Note the following examples:
^ If the figure obtained in step 8 was 3.53 mm (0.139 inch), use a 3.30 mm (0.130 inch) shim.
^ If the figure obtained in step 8 was 3.30 mm (0.130 inch), use a 3.05 mm (0.120 inch) shim.

Alternate Adjustment Method

1. Install the original shim to the shaft.Use the chassis grease in order to hold the shim in place.

Important:
Use this method only if the proper tools for calculating the shim size are unavailable.


2. Install the assembled axle tube and the shaft to the carrier. Do not use sealer at this time.

3. Install the bolts.
^ Tighten the bolts to 40 Nm (30 ft. lbs.).

Notice: Refer to Fastener Notice in Service Precautions.






4. Measure the shaft end play using the following procedure:
1. Install the J 8001 or the equivalent on the axle tube end.The plunger of the indicator must be at a right angle to the axle flange.
2. Move the shaft back and forth and read the end play.The correct end play is 0.03-0.51 mm (0.001-0.020 inch).
3. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range.