- Install a NEW spacer on drive pinion. Install drive pinion into differential carrier. Using a press, temporarily press in bearing until threaded portion is protruding .12" (3 mm) without crushing spacer. Apply gear oil to the threaded portion of drive pinion.
- Using drive pinion holding tool install drive pinion nut. Apply gear oil to bearings. Snug down bearing by turning drive pinion several times. Using a torque wrench, check bearing preload. Preload should be 4.3-8.7 INCH lbs. (.5-1.0 mm) for NEW bearings and 2.6-4.3 INCH lbs. (.3-.5 mm) for used bearings.
- If adjustment is needed, tighten drive pinion nut to 108 ft. lbs. (146 N.m). Measure preload. If preload is excessive, replace spacer and readjust. If preload is insufficient, increase torque in increments of 5-10 ft. lbs. (7-14 N.m) until proper preload is obtained, but DO NOT
exceed 268 ft. lbs. (363 N.m)
NOTE:
If preload in not within specification after tightening nut to maximum, a NEW spacer must be used.
- Install differential case, outer races and side washer on side nearest ring gear. Be sure ring gear has backlash. Snug down washer and bearing by tapping on ring gear with a plastic hammer. Push side bearing boss on teeth surface of ring gear and measure backlash. Backlash should be .0039" (.10 mm).
- Select proper washer using backlash as reference. Side washers come in 23 different sizes ranging from .1028-.1295" (2.61-3.29 mm). After proper backlash side washer has been installed on side nearest ring gear, select a side washer for side farthest from ring gear, of a thickness which eliminates any clearance between outer race and housing.
- Remove side washers and differential case. Install side washer into ring gear side of housing. Place other side washer on bearing race opposite ring gear and install differential case with outer race into housing. Using a plastic hammer, snug down washer and bearing by tapping on ring gear.
- Using a dial indicator, measure ring gear backlash. It should be .0039-.0059" (.10-.15 mm). If not within specification, adjust by either increasing or decreasing number of washers on both sides by an equal amount. Insure that there is ring gear backlash and there should be no clearance between side washer and case.
- After adjustment, using backlash as reference, remove ring gear side washer and measure thickness. Install a NEW washer .0024-.0035" (.06-.09 mm) thicker than washer removed.
NOTE:
Select a washer which can be pressed in 2/3 of the way by finger.
- Use a plastic hammer to tap side washer in rest of the way. Recheck ring gear backlash. It should be .0039-.0059" (.10-.15 mm). If not within standard, adjust by either increasing and decreasing washers on both sides by an equal amount.
NOTE:
The backlash will change about .0008" (.02 mm) with a .0012" (.03 mm) variation of the side washer.
- Install side bearing caps and tighten bolts to specifications. To measure total preload, apply gear oil on bearings, turn drive pinion left and right several times and with a torque wrench measure total preload. Preload (starting) should be 2.6-4.3 INCH lbs. (.02-.03 N.m), in addition to drive pinion preload.
NOTE:
If preload is not within standard, readjust ring gear side washer.
- Measure ring gear backlash using a dial indicator. Measure at three places on outer edge of ring gear. Backlash should be .0039-.0059" (.10-.15 mm).
NOTE:
If not within standard, adjust by either increasing or decreasing washers on both sides by an equal amount. The backlash will change about .0008" (.02 mm) with a .0012" (.03 mm) variation of the side washer.
- To inspect teeth contact between ring gear and drive pinion, coat red lead on three or four teeth at three different positions of ring gear, rotate ring gear in both directions and inspect teeth pattern. If there is toe contact, replace pinion plate washer with a thinner one. If there is heel contact, replace pinion plate washer with a thicker one.
NOTE:
If the plate washer thickness is altered .0039" (.10 mm), the center of the teeth contact will change about 1/8 of the total teeth surface.
- If there is flank contact, increase backlash within standard specification. If there is face contact, decrease backlash within standard specification.
NOTE:
Increase or decrease both side washers by an equal amount. The backlash will change about .0008" (.02 mm) with a .0012" (.03 mm) variation of the side washer.
- Stake drive pinion nut using a chisel. Install differential carrier oil seal .331-.354" (8.4-9.0 mm) below surface using a hammer and seal installer. Install differential carrier cover and gasket and bolts.
- After wrapping spline with tape, install governor pressure adapter and governor body. Assemble with transmission.