200 Series Solid Type Axle

1. Ensure all parts are clean and that bearings are well lubricated with suitable oil.
2. Install carrier and bearings into final drive housing.
3. Install side bearing spacer in position on ring gear end of carrier.
4. Install both of the original carrier side bearing preload shims on carrier end (opposite ring gear).
5. Install side bearing caps and cap attaching bolts. Torque attaching bolts to 65-72 ft. lbs. and tap on caps with suitable hammer to seat bearings.
6. Turn carrier several times to seat bearings, then measure carrier turning force with suitable spring scale. Turning force at ring gear bolt should be 8-9 lbs.
7. If turning force is not as specified, correct by adding to or subtracting from the total amount of shim thickness.
8. Press in front and rear bearing outer races, then install selected pinion height adjusting washer in drive pinion and press in rear bearing outer race.
9. Place pinion front bearing inner race in gear carrier.
10. Apply suitable lubricant to cavity at sealing lips of oil seal, then install front oil seal.
11. Install drive pinion spacer, drive pinion bearing and drive pinion in gear carrier.
12. Install companion flange into drive pinion using a suitable hammer.
13. pinion nut 94 ft. lbs. Ensure threaded portion of drive pinion and pinion nut are free from oil or grease.
14. Tighten pinion nut by degrees until preload is 10-15 inch lbs. When checking preload, turn drive pinion several times in both directions to seat bearings.
15. Install differential case assembly with side bearing outer races into gear carrier.
16. Install right and left side bearing adjusting washers in position between side bearing and carrier, then drive in side bearing spacer using a suitable tool.
17. Align mark on bearing cap with mark on gear carrier and install bearing cap on gear carrier.
18. Measure ring gear to drive pinion backlash with dial indicator. If backlash is less than .0051-0071 inch, decrease thickness of left shim and increase thickness of right shim by same amount. If backlash exceeds .0051-.0071 inch, increase thickness of right shim and decrease thickness of left shim by same amount. Never change the total amount of shims to prevent changing bearing preload.
19. Check total preload, which should be 10-20 inch lbs. If preload is too great, remove same amount of shims from each side. If preload is too small, add same amount of shims to each side.
20. Recheck ring gear to drive pinion backlash and check runout of gear. If backlash varies excessively in different places, foreign matter may be trapped between ring gear and differential case.
21. If backlash varies greatly and ring gear runout is .0031 inch or less, the hypoid gear set or differential case needs to be replaced.