Adjustment

ADJUSTMENT

PINION BEARING PRELOAD


NOTE: Pinion bearing preload is controlled and adjusted by means of a select-thickness spacer sandwiched between the pinion head and tail bearing cones.




1. Remove pinion housing bolts (1) and remove pinion housing assembly from axle housing.




2. Using a dial-type torque wrench (1), measure pinion housing rotating torque. Rotating torque should be within 130-260 N. cm (12-23 in. lbs.). If rotating torque is below this range, disassemble pinion housing, measure and install a slightly thinner spacer (1), reassemble and reverify. If rotating torque is above this range, disassemble pinion housing, install a slightly thicker spacer, reassemble and reverify rotating torque.




3. Using Spanner Wrench 6958 (2), remove pinion flange nut.




4. Using Puller 1026 (1), remove pinion flange.




5. Press pinion gear (2) out of housing.




6. Remove pinion bearing preload spacer (1).




7. Measure spacer (1) and correct per rotating torque measurement.




8. Install proper pinion bearing preload spacer (1).




9. Install pinion gear/bearing assembly to housing. Using Installer L-4507 (1), press pinion tail bearing (2) onto shaft until it bottoms.




10. Using Installer L-4507 (1), press on pinion flange (2).




11. Install and torque (1) pinion flange nut to 475 Nm (350 ft. lbs.).




12. Install pinion housing assembly and depth shim to axle assembly.
13. Install and torque pinion housing-to-axle housing bolts (1) to 34 Nm (25 ft. lbs.).

DIFFERENTIAL SIDE BEARING PRELOAD


NOTE: Differential side bearing preload is controlled and adjusted by means of select-thickness shims sandwiched between the side bearing cups and the housing/cover.

NOTE: For accurate results, differential side bearing preload must only be measured when the pinion housing assembly is removed from the axle.




1. Remove pinion housing-to-axle housing bolts (1).




2. Remove pinion housing and depth shim (1) from axle assembly.




3. Install Torque Tool C-4995 (1) to differential housing as shown. Measure and record differential rotating torque. Differential rotating torque should be within 190-260 N. cm (17-23 in. lbs.). If rotating torque is below this range, disassemble housing, measure and install slightly thicker preload shims (1). Add thickness equally to both sides. If rotating torque is above this range, disassemble housing, measure and install slightly thinner preload shims. Remove thickness equally from both sides.




4. Remove axle housing cover (5) and differential assembly (3).




5. Remove differential side bearing cup from axle housing cover. Install Bearing Remover 6514 (1).




6. Remove differential side bearing cup with Bearing Remover 6514 (1).




7. Remove side bearing preload shim (1).




8. Measure preload shim (1) to identify for replacement.




9. Install new differential side bearing preload shim (1) into axle housing cover (2).




10. Using Handle C-4171 and Installer D-129 press new side bearing cup into cover until it bottoms. Use suitable cup (3) to support and protect cover.




11. Using Remover 9664 (1) and Slide Hammer C-637 (2), remove differential side bearing (inboard) cup.




12. Measure preload shim (1) to identify for replacement.
13. Install new differential side bearing preload shim (1) into axle housing.
14. Using Handle C-4171 and Installer D-145, press differential side bearing cup into housing until it bottoms.




15. Install differential/ring gear assembly (3), new cover O-ring seal (4), and cover (5).
16. Install and torque cover-to-housing bolts to:

- M10x40 - 65 Nm (48 ft. lbs.)
- M8x25 - 34 Nm (25 ft. lbs.)





17. Again verify rotating torque measurement (1). Repeat adjustment procedure until proper rotating torque is obtained.




18. Install pinion housing assembly and depth shim (1). Use new O-ring on housing.




19. Install and torque pinion housing-to-axle housing bolts (1) to 34 Nm (25 ft. lbs.).