Adjustment of Drive Gear and Drive Pinion Assembly
Adjustment of Drive Gear and Drive Pinion AssemblyDRIVE PINION HEIGHT ADJUSTING WASHER SELECTION
^ Drive gear and pinions are supplied in matched sets only. Matching numbers on both pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers / of each pinion gear and drive gear before proceeding with assembly.
^ The mounting distance from the centerline of the drive gear to the back face of the pinion gear for the Model 205 axle assembly is 103.5 mm (4.0748 inches).
On the button end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0), which indicates the best running position for each particular gear set. This dimension is controlled by a selective shim between the inner pinion bearing race and pinion gear.
For example: If a pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less shim than a pinion etched "0". This means decreasing shim thickness; increases the mounting distance of the pinion to 103.6 mm (4.0778 inches). If a pinion is etched m+8 (-3), it would require adding 0.08mm (0.003 inch) more to the shim than would be required if the pinion were etched "0". By adding 0.08 mm (0.003 inch), the mounting distance of the pinion was decreased to 103.4 mm (4.0718 inches) which is just what m-8 (a-3) etching indicated.
^ To change the pinion adjustment, use different shims which come in different thickness.
^ Use the following tables as a guide for selecting the correct shim thickness to add or subtract from the old shim.
PINION GEAR HEIGHT
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool.
Tool number A: - (8144)
Tool number B: - (6740)
Tool number C: - (6741)
3. Install pinion bearing inner race and pinion height adjusting washer to gear carrier using Tool as shown.
4. Turn the assembly several times to seat the bearings.
5. Measure the turning torque. Tool number: ST3127SOOO (J-25765-A)
Turning torque specification: 2.98 - 4.76 Nm (0.31 - 0.48 Kg-m, 27 - 42 inch lbs.)
6. Tighten side-bearing cap to the specified torque installing Tools as shown in the figure.
Tool number A: - (6739)
Tool number B: - (D-115-2)
Tool number C: - TBD
Tool number D: - (D-115-3)
7. Put scooter block on pinion height block. Make sure that dial gauge is level adjusting pressure with a hand. Dial gauge indicates "0".
8. Slide dial gauge along arbor. Record the maximum.
9. Adjust pinion height adjusting washer so that the maximum will be "0".
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion.
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Thoroughly clean drive gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the equivalent. Apply it to 3 or 4 teeth of drive gear drive side.
3. Hold companion flange steady by hand and rotate the drive gear in both directions.
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit rear bearing outer race with Tools.
Tool number A: ST30901000 ( - )
Tool number B: KV40105230 ( - )
2. Press-fit front bearing outer race with Tools.
Tool number A: ST35271000 ( - )
Tool number B: KV40104810 ( - )
3. Select drive pinion height adjusting washer.
4. Install drive pinion adjusting washer in drive pinion, and press-fit pinion rear bearing inner race in it, using a press and Tool.
Tool number: - (C - 4040)
5. Place pinion front bearing inner race in gear carrier.
6. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal, using Tools.
Tool number A: KV38100500 (J-25273)
Tool number B: KV38102200 ( - )
7. Place collapsible spacer, drive pinion height adjusting washer and drive pinion in gear carrier.
8. Insert companion flange onto drive pinion. Tap the companion flange with a soft hammer until fully seated.
9. Tighten pinion nut until total preload is within specification.
^ The threaded portion of drive pinion and pinion nut should be free from oil or grease.
Tool number: KV38108300 (J-44195)
10. Tighten the pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn the drive pinion in both directions several times to set the bearing rollers.
Tool number: ST3127S000 (J-25765-A)
Pinion bearing preload: 2.3 - 3.4 Nm (24 - 34 kg-cm, 21 - 30 inch lbs.)
This procedure will have to be repeated if:
^ Maximum preload is achieved before the minimum pinion nut torque is reached.
^ Minimum preload is not achieved before maximum pinion nut torque is reached.
INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY
1. Install side bearing adjust nut into gear carrier.
2. Install differential case assembly with side bearing outer races into gear carrier.
3. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
^ Do not tighten at this point. This allows further tightening of side bearing adjusters.
4. Tighten each side bearing adjust nuts alternately turning drive gear.
5. Measure backlash of drive gear and drive pinion using a dial gauge.
Drive gear to drive pinion back lash: 0.13 - 0.18mm (0.0051 - 0.0071 inch)
6. Use each adjust nut to adjust backlash.
7. In case of lots of backlash, loosen adjust nut A and tighten adjust nut B. In case of less backlash, loosen adjust nut B and tighten adjust nut A.
8. After adjusting backlash, fix adjuster with screws and tighten cap bolt to the specified torque.
9. Check total preload with tool.
Tool number: ST3127S000 (J-25765-A)
Total preload (With oil seal): 2.98 - 4.76 Nm (0.31 - 0.48 Kg-m, 27 - 42 inch lbs.)
10. Check tooth contact.
11. Install rear cover. Apply liquid sealant to rear cover side and install gear carrier.
12. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal.
13. Install O-ring and extension tube.
14. Install sides haft and side flange.