Pinion Depth Adjustment (195/218 mm Axle)

Pinion Depth Adjustment (195/218 mm Axle)

Special Tools

* DT 49911 - Pinion Shim Gauge Plate

* J-8001 - Dial Indicator Set

* J-21777-B - Pinion Setting Gauge Set

* J-34925 - Pinion Setting Gauge and Components

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Note:
Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.

1. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations [1][2]Fluid Type Specifications.

2. Install the pinion bearings into the axle housing.





3. Position the following tools in the differential carrier.

* For the 195 mm axle, use the J-21777-40 (1), the J-21777-43 (2), and the DT 49911 - plate(4).

* For the 218 mm axle, use the J-21777-8 (1), the J-21777-43 (2), the J-21777-42 (3), and the DT 49911 - plate(4).

4. Using a torque wrench, tighten the nut on the J-21777-43 until the specified rotating torque is obtained.

* For the 195 mm axle, 2.0-2.6 Nm (18-23 lb in) for NEW bearings or 1.0-2.3 Nm (9-20 lb in) for used bearings.

* For the 218 mm axle, 2.1-3.1 Nm (19-27 lb in) for NEW bearings or 1.0-2.3 Nm (9-20 lb in) for used bearings.

5. Rotate the assembly several times in both directions in order to seat the pinion bearings and re-check the torque.

* For the 195 mm axle, if the torque is less than 2.0 Nm (18 lb in) for NEW bearings or 1.0 Nm (9 lb in) for used bearings, tighten until a rotating torque of 2.0-2.6 Nm (18-23 lb in) for NEW bearings or 1.0-2.3 Nm (9-20 lb in) for used bearings is obtained.

* For the 218 mm axle, if the torque is less than 2.1 Nm (19 lb in) for NEW bearings or 1.0 Nm (9 lb in) for used bearings, tighten until a rotating torque of 2.1-3.1 Nm (19-27 lb in) for NEW bearings or 1.0-2.3 Nm (9-20 lb in) for used bearings is obtained.





Note:

* For the 195 mm axle, ensure that the smaller diameter of the J-21777-45 (1-2) is facing outward toward the sides of the differential carrier.

* Use the shorter (17 mm) step of the DT 49911 for the 195 mm axle. And the taller (29 mm) step for the 218 mm axle.

6. Position the J-21777-45 (1-2) and the J-21777-1 (3) in the differential carrier and align the J-21777-1 (3) with the DT 49911 - plate(2).





7. Using the J-8001 - set(1) and set at zero, move the J-21777-1 (2) back and forth and recheck the zero setting. Readjust if needed.

8. Rotate the J-21777-1 (2) away from the DT 49911 - plate(2) until it no longer touches the DT 49911 - plate(2).

9. The value indicated on the J-8001 - set(1) is the thickness of the shim needed for the correct pinion depth.

Note:
Measure the shim to ensure that the shim is the correct thickness.

10. Select the shim that is the proper thickness.

11. Remove the tools and pinion bearings.

12. Install the pinion shim between the pinion gear and the inner pinion bearing. Refer to Differential Drive Pinion Gear Bearing Replacement (195/218 mm Axle) Differential Drive Pinion Gear Bearing Replacement (195/218 mm Axle)Differential Drive Pinion Gear Bearing Replacement (250 mm Axle) Differential Drive Pinion Gear Bearing Replacement (250 mm Axle).