Part 2
Differential Bearings - Dana 70Steps 34-66
34. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
35. Install the outer pinion bearing.
36. Install the pinion flange.
37. Use the special tool to prevent the flange from turning while installing the old washer and the locknut.
^ Tighten to 339 Nm (250 ft. lbs.)
38. Using a Nm (inch lbs.) torque wrench, rotate the pinion. The torque must read as specified.
^ To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.
39. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the locknut and the washer. Use the special tool to prevent the flange from turning.
40. Using the special tool, remove the pinion flange.
41. Lubricate the pinion seal rubber lips.
^ Use Premium Rear Axle Lubricant.
42. Using a suitable driver, install the pinion seal.
^ After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.
43. Coat the inside of the pinion flange with a small amount of rear axle lubricant.
44. Install the pinion flange.
^ Align the index marks of the pinion flange and pinion stem.
45. CAUTION: Always install a new washer and locknut.
Use the special tool to prevent the flange from turning while installing the new washer and locknut.
^ Tighten to 339 Nm (250 ft. lbs.)
46. Position the differential carrier assembly with the Master Bearings in the axle housing. Install the special tools and locate the tip of special tool 308-021 on a flat surface.
47. NOTE: Repeat this step and the next step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
48. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.
49. Remove the special tools and the differential case from the differential housing.
50. Remove the Master Bearings from the differential case.
51. Place one shim, of the necessary thickness, as determined from the previous measurement, on the LH side of the differential case.
If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
52. Using the special tool, install the differential bearing on the LH side of the differential case.
53. Determine the correct shim thickness and place it on the differential case hub on the RH side.
^ To determine the correct shim thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 inch) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
54. Using the special tools, install the differential bearing.
1 Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
2 Using the special tool, drive the differential bearing onto the hub.
55. Assemble the differential bearing cups to the differential bearings.
56. CAUTION: Do not spread the differential housing more than specified.
CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
Using the special tools, spread the differential housing to the specification.
^ Use a rawhide hammer to seat the differential into the differential housing pocket.
^ Remove the special tools.
57. CAUTION: Match the mating letters as noted during disassembly.
Install the bearing caps, aligning the letters with those on the differential housing.
^ Tighten to 108 Nm (80 ft. lbs.)
58. Confirm the total preload.
^ Using a Nm (inch lbs.) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) with new bearings installed as recommended:
^ 3.54 and 3.73 = 0.9 Nm (8 inch lbs.)
^ 4.10 and 4.56 = 0.8 Nm (7 inch lbs.)
^ 4.63 and 5.13 = 0.8 Nm (7 inch lbs.)
^ If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
59. Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.
60. Carry out the tooth contact pattern check to verify the final pinion position is correct.
61. Install the axle shafts.
62. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the threads of the original bolts.
Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the new bolts.
^ Tighten to 112 Nm (83 ft. lbs.)
63. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.
CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.
NOTE: The differential housing cover uses silicone rubber sealant as a gasket.
Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
64. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
^ Use the 2 bolts to position the differential housing cover on the differential housing.
65. Install the remaining bolts. Tighten the bolts alternately and evenly.
^ Tighten Grade 5 bolts to 47 Nm (35 ft. lbs.)
^ Tighten Grade 8 bolts to 61 Nm (45 ft. lbs.)
^ Allow one hour cure time before filling the axle with the correct amount of specified lubricant.
66. Fill the axle with the specified type and amount of lubricant.