Side Bearing & Drive Gear

1. Install side bearing inner race into differential case using tool MB990802 or equivalent.
2. For front differentials, adjust drive gear backlash as described under ``STARION, Differential Case Assembly,'' steps 12a through 12h. In step 12h note that drive gear backlash is .005-.007 inch for front differentials.
3. For rear differentials, proceed as follows:
a. Position differential case assembly into gear carrier, then install carrier cap and cap nuts. Tighten cap nuts finger tight only.
b. Install side bearing nut to carrier cap and torque to 40-47 ft. lbs.
c. Install side bearing nut on each side of drive gear using tool MB990201 and tighten to 11 lbs. Turn bearing nuts in and out several times until they operate smoothly before final tightening.

Fig. 29 Measuring drive gear backlash.:

d. Measure drive gear backlash, Fig. 29. Backlash should measure .005-.007 inch. If backlash is less than .005 inch, loosen side bearing nut on back side of drive gear and tighten nut on front side of gear by the same amount.
e. When backlash has been adjusted within specifications, tighten both side bearing nuts by a half pitch to preload side bearings. One pitch equals the space between two adjacent holes on the side of the side bearing nuts.
f. Install lock plate and torque attaching nut to 11-15 ft. lbs.

Fig. 19 Checking gear tooth contact:

Fig. 20 Gear tooth contact pattern chart:

4. Check drive gear and drive pinion for proper tooth contact by applying suitable marking compound to both surfaces of drive gear teeth. Insert a brass rod between carrier and case and rotate yoke end by hand one revolution in each direction, Fig. 19, while applying a load of approximately 2 ft. lbs. to the drive pinion. Adjust pinion height and backlash as needed until tooth contact pattern resembles standard pattern, Fig. 20.

Fig. 30 Measuring drive gear runout:

5. Measure drive gear runout using suitable dial indicator, Fig. 30. If runout exceeds .002 inch, change position of drive gear in differential and recheck. If runout still exceeds specification, replace drive gear or differential case as needed.