Ring Gear and Pinion Backlash

1. Place differential assembly (with pinion installed) into housing. Differential master bearings should still be assembled to case.




2. Set up dial indicator Tool 4201-C or equivalent. Force ring gear into mesh with the pinion. Rock ring gear to allow the teeth of the gears to mesh. With force still applied to the differential case, set indicator at zero.




3. Force the differential case (ring gear) away from the pinion gear to obtain an indicator reading. Repeat until the same reading is obtained each time. This reading will be the necessary amount of shims required between the differential case and differential bearings on the ring gear side. Remove indicator and differential case from the carrier. Remove master bearings from differential case.

4. As determined in Step 3, place the required amount of shims on the ring gear hub of the differential case. For example: if the reading in Step 3 was 1.1 4mm (0.045 inch), place 1.14mm (0.045 inch) amount of shims on the hub of the ring gear side of the differential case.




5. Install the bearing cone on the ring gear side of the differential case. Drive the bearing onto the hub using Differential Side Bearing Replacer, D81T-4221-A or equivalent as shown.

6. To determine the correct amount of shims to be placed on the hub of the drive pinion side of the differential case, subtract the reading obtained in Step 3 from the total differential case end play. Total case end play was determined under Steps 9 and 10 of Differential Case-Assembly. When this amount is determined, add 0.36mm (0.015 inch) to the amount. This is the required amount of shims to be placed on the hub of the drive pinion side of the differential case.

For example: Total Differential Case End Play was 2.30mm (0.091 inch). The reading in Step 3 was 1.14mm (0.045 inch), and when subtracted from 2.30mm (0.091 inch) gives 1.16mm (0.046 inch). 0.38mm (0.015 inch) is added to give 1.52mm (0.061 inch) amount of shims to be placed on the hub of the drive pinion side of the differential case.

7. Place the required amount of shims on the hub of the drive pinion side of the differential case.

8. Install the bearing cone on the hub of the drive pinion side of the differential case. Place Step Plate D80L-630-7 or equivalent for Model 60 axles on the ring gear side bearing to protect the bearing during installation of the drive pinion side bearing. Place the bearing on the drive pinion side hub and drive it on using Differential Side Bearing Replacer, 081T-4221-A or equivalent.




9. Install spreader and indicator to carrier. Remove indicator.

CAUTION: Do not spread carrier over 0.38mm (0.015 inch).

10. Assemble differential bearing cups to differential bearing cones.

Install differential assembly into carrier.




Use a rawhide hammer to seat differential assembly into crossbore of carrier. Care should be taken to avoid nicking the teeth of the ring gear and pinion during assembly. Remove the spreader from the differential case.




11. Install bearing caps. Make sure the letters stamped on the caps correspond with those on the carriers. Tighten bearing cap screws to torque specifications.




12. Check ring gear and pinion backlash in three equally spaced points with dial indicator.

Backlash tolerance is 0.13-0.23mm (0.005-0.009 inch) and cannot vary more than 0.O5mm (0.003 inch) between points checked.

High backlash is corrected by moving the ring gear closer to the pinion.

Low backlash is corrected by moving ring gear away from the pinion.

These corrections are made by switching shims from one side of the differential case to the other.

13. Obtain a gear tooth contact pattern. Check as outlined under Gear Tooth Contact Pattern Check prior to complete reassembly.




14. Install new cover gasket and install cover plate. Tighten screws to torque specifications.

NOTE: The flat mounting surface cover plate on Dana design axles requires the use of a silicone rubber sealer material, Silicone Rubber D6AZ-19562-AA (clear) or D6AZ-19562-BA (black) (ESB-M4G92-A and ESE-M4G195-A) or equivalent rather than a gasket.

The cover face of the carrier and the flat surface of the cover plate must be free of any oil film or foreign material.

Sealant material must meet specifications of D6AZ-19562-AA or BB (ESB-M4G92-A), or equivalent.

Apply RTV Silicone Rubber Sealer D6AZ-19562-AA or BA, or equivalent to cover plate surface. Ensure that the sealer bead is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.

The bead is to be 3.18-6.35mm (1/8 to 1/4 inch) wide.

Install two cover screws into cover at 8 o'clock and 2 o'clock positions. Use these two holes to guide cover plate into position on the carrier.

Install remaining screws. Tighten alternately and evenly. Tighten screws to 41-54 Nm (30- 40 ft-lb).

Allow one hour curing time before filling carrier with the proper amount of specified lubricant and vehicle operation.

15. Install the axle shafts as described under Axle Shaft in the Removal and Installation. Connect the steering linkage to the spindle.