10.5 Inch Axle

Removal Procedure

^ Tools Required
- J 22912-01 Bearing Remover
- J 7872 Mag Base and Indicator
- J 34672 Depth Gauge
- J 34673 Straight Edge (Oil Pan)
- J 26900-2 Micrometer





1. Remove the ring gear and the differential side bearings. Refer to Drive Axle Disassemble.
2. Remove the case screws. Set the unit on the right side case half.
3. Remove the case halves.
3.1. Pry the halves apart at the yoke hole location.
3.2. Hold the side gear in the left side case half.
4. Remove the governor assembly.
5. Remove the latching bracket assembly.
6. Remove the left side gear.
7. Remove the left side clutch plates and the guide clips.
8. Remove the left side gear thrust washer.
9. Remove the following parts:
^ The reaction blocks
^ The pinion yoke
^ The pinion gears
^ The pinion thrust washers
10. Remove the right cam unit from the differential.
11. Remove the right side gear thrust washer. Measure and record the overall length of the gear assembly from the front of the gear to the back of the thrust sleeve including the side gear thrust washer.
12. Remove the thrust sleeve using the J 22912-01. Press the sleeve from the side gear.





13. Remove the clutch plates.
14. Remove the guide clips.
15. Remove the wave washer.
16. Remove the cam plate.
17. Remove the side cam gear.

Cleaning and Inspection Procedure





1. Clean all the parts with an approved solvent.

Important: If any damage to the differential case is found, the differential must be replaced.

2. Inspect the following parts:
^ The pinion gear and the side gear for wear, cracks, scoring, and spalling
^ The thrust washers for wear
^ The fit of the side gears on the axle shafts
^ The differential case for cracks and scoring
^ The thrust sleeve for excessive wear
Do not replace the thrust sleeve unless necessary.
^ All the parts for excessive wear and breakage
3. Replace parts as necessary.
4. Inspect the side gear bore for scoring.
If scoring is present, replace the differential.


Cam Unit Assembly
1. Install a cam plate to the side cam gear.
2. Install a wave washer.
3. Install the clutch plates.
Alternate the plates. Position the wave washer as shown.
4. Install the thrust sleeve.
Press the thrust sleeve flush with the side gear disc spline.
5. Install the guide clips to the plates.
5.1. Use a chassis grease in the clips in order to hold the clips in place on the plates.
5.2. If the side gear or the thrust sleeve has been replaced, measure and record the overall length of the gear to the back of the thrust sleeve including the side gear thrust washer.
5.3. Compare the reading with the reading obtained earlier.
5.4. If the new reading is more than 0.0762 mm (0.003 inch) higher or lower than the original, select a side gear thrust washer that will return the reading closest to the original reading.

Adjustment of the Differential





1. If it is necessary to replace the cam gear, the right hand side gear, or the reaction blocks, the entire differential must be adjusted. The differential is adjusted using selective thickness thrust washers behind each side gear, and the selective thickness thrust washers between the reaction blocks.
2. Build up the differential properly.
The proper clearance between parts is critical to the operation of the unit.
3. Note the 3 adjustments necessary as follow:
^ The left side gear backlash
^ The right side gear backlash
^ The thrust block clearance

Right Side Gear Backlash Adjustment
1. Install the cam unit and the side gear thrust washer to the right case half.
2. Clamp the cam unit in place using a set of washers, a nut, and a bolt long enough to hold the cam unit in place.
3. Place the pinion gears and the pinion thrust washers on the pinion yoke.





4. Install the yoke firmly to the differential case half.
5. Loosen the nut.
6. Index 1 pinion gear tooth to point downward, perpendicular to the case half face.
Tighten the nut.





7. Mount a J 7872 on the case half face using a magnetic base.
8. Place the stem of the dial indicator on the pinion gear tooth.
9. Pull the pinion gear firmly into the seat.
^ Rotate the gear back and forth while reading the dial indicator.
^ Record the reading.
^ Do not unseat the pinion yoke.
This will make the backlash reading inaccurate.
10. Repeat steps 5 through 9 on the remaining 2 pinions.
11. The backlash should be between 0.254 - 0.457 mm (0.010 - 0.018 inch).
12. If the backlash is too high, use a thicker side gear thrust washer.
13. If the backlash is too low, use a thinner side gear thrust washer.

Left Side Gear Backlash Adjustment





1. Assemble the clutch plates.
Alternate the plates as shown.
2. Assemble the guide clips to the plates.
Use grease in the clips in order to hold the clips in place on the plates.
3. Install the following parts to the differential:
^ The side gear thrust washer
^ The clutch plate assembly
^ The left side gear





4. Clamp the side gear in place using a set of washers, a nut, and a bolt long enough to hold the side gear in place.
5. Place the pinion gears and the pinion thrust washers on the pinion yoke.





6. Install the yoke firmly to the differential case half.
7. Loosen the nut and the index one pinion gear tooth to point downward, perpendicular to the case half face.
Tighten the nut.





8. Mount a J 7872 on the case half face using a magnetic base.
9. Place the stem of the J 7872 on the pinion gear tooth.
10. Pull the pinion gear firmly into the seat.
^ Rotate the gear back and forth while reading the dial indicator.
^ Record the reading.
^ Do not unseat the pinion yoke. This will make the backlash reading inaccurate.
11. Repeat steps 7 through 10 on the other two pinions.
12. The backlash should be between 0.051 and 0.254 mm (0.002 and 0.010 inch).
13. If the backlash is too high, use a thicker pinion thrust washer.
14. If the backlash is too low, use at a thinner position thrust washer.

Reaction Block Clearance Adjustment





1. Install the left side gear thrust washer, the clutch plates, and the side gear.
Bolt the parts into position. Refer to Left Side Gear Backlash Adjustment.
2. Install the right side gear thrust washer and cam assembly.
Bolt the parts into position. Refer to Right Side Gear Backlash Adjustment.
3. Measure the distance from the side gear face to the case half face.
3.1. The thickness of the straight edge must be subtracted from the reading.
3.2. Add the measurement of both sides together. This is the side gear spread.





4. Use the J 26900-2 in order to measure the thickness of the original reaction blocks and the reaction block thrust washers together.
5. If the combined reaction block and the thrust washer thickness is not 0.000 to 0.1524 mm (0.000 to 0.006 inch) less than the side gear spread, adjust the clearance using the following procedure:
^ Select a new reaction block thrust washer of the correct thickness in order to obtain 0.000 to 0.1524 mm (0.000 to 0.006 inch) clearance.
^ Reshim the left and/or the right clutch disc pack.
Maintain the side gear backlash. Refer to Right Side or Left Side Gear Backlash Adjustment.
^ Some of the older locking differentials had select fit reaction blocks without a between thrust washer. These models require replacing the reaction blocks with the correct thickness reaction block.

Assembly of the Differential





1. Install the right thrust washer.
2. Install the right cam unit. Refer to Cam Unit Assembly.
3. Install the following parts:
^ The reaction blocks
^ The reaction block thrust washer
^ The pinion yoke
^ The pinion gears
^ The pinion thrust washers
4. Install the left thrust washer. Assemble the plates as shown.
5. Install the left side gear.
6. Install the latching bracket assembly.
7. Install the governor assembly.
The straight end of the latching bracket spring must be over and outside the governor assembly shaft.
8. Install the case halves together.
Hold the side gear in the left side case half.
9. Install the case screws.
10. Install the ring gear and the differential side bearings. Refer to Assembly of the Rear Axle in 10 1/2 Inch Ring Gear.