Assembly
Differential Case AssemblyInstallation Procedure
Tools Required
- J 25299 Differential Side Bearing Installer
- J 8092 Driver Handle
- J 8107-2 Differential Side Bearing Remover Plug
1. Lubricate all the parts with axle lubricant.
2. Install the thrust washers to the side gears.
3. Install the side gears to the differential case on the same side in which the parts were removed.
4. Place one pinion gear on the side gear. Rotate the gear until the pinion is exactly opposite the differential opening.
Install the pinion gears to the differential without the thrust washers.
5. Rotate the pinion gears into place. Verify the gears line up with the pinion shaft holes.
6. Install the pinion shaft.
7. Install the pinion shaft lock bolt. Apply Loctite 242.
Tighten
Tighten the pinion shaft lock bolt to 34 N.m (25 lb ft).
8. Inspect the mating surfaces of the differential case for cleanliness, and that the surfaces are free of burrs.
9. Install the ring gear to the differential case.
10. Install two threaded studs into the ring gear on opposite sides.
11. Place the ring gear on the case. Align the studs with the holes in the case.
12. Install the ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case.
Tighten
Tighten the ring gear bolts in sequence to 120 N.m (90 lb ft).
13. Install the differential side bearings, using J 25299, J 8092, and J 8107-2.
- In order to protect the differential case, place J 8107-2 in the case on the side opposite the bearing installation
- Drive the bearing onto the case using J 25299 and J 8092.
14. Install the differential case to the axle housing.
Side Bearing Preload Adjustment
Adjustment Procedure
Tools Required
J 22779 Side Bearing Backlash Gauge
- Before installing the drive pinion, make a differential side bearing preload adjustment.
- In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right shims equally.
- Measure the production shims and the spacers one at a time. Add the measurements together in order to obtain the sizes of the right and the left shim packs. Production shims are cast iron. Do not reuse production shims.
- Service spacer thickness is nominal at 4.32 mm (0.170 in).
- Service shims are available from 1.02-2.54 mm (0.040-0.100 in) in increments of 0.101 mm (0.004 in).
- The side bearing surfaces must be clean and free of burrs.
1. Place the case, with the bearing cups installed, into the axle housing.
1. Lubricate the axle bearings with axle lubricant.
2. Support the case in order to keep the case from falling into the axle housing.
2. Insert J 22779 between the axle housing and the left bearing cup.
3. Turn the adjusting nut to the right until you produce a noticeable drag, while moving the tool back and forth in the bore.
1. Tighten the lock bolt on the side of the tool.
2. Leave the tool in place.
4. Install a service spacer and a shim between the right bearing cup and the axle housing.
Insertion of progressively larger feeler gauge sizes between the axle housing and the service shim determines the bearing preload.
1. Push the feeler gauge downward so that the feeler gauge contacts the shim at the top and the bottom, and then contacts the axle housing.
2. The correct feeler gauge thickness is the point just before additional drag begins. This is the zero setting without the preload.
5. Remove the following from the vehicle:
1. The strap
2. J 22779
3. The service spacer
4. The service shim
5. The feeler gauge
6. The differential case from the axle housing
6. Measure J 22779 gauge plate thickness in three places using a micrometer. Average the readings.
7. Add the readings of the right side service spacer, the service shim, and the feeler gauge.
8. For the initial backlash setting, move the ring gear from the pinion by subtracting 0.25 mm (0.010 in) from the ring gear side shim pack and adding 0.25 mm (0.010 in) to the shim pack on the opposite side.
9. In order to obtain the proper preload on the side bearings, add 0.10 mm (0.004 in) to the measurement of each shim pack.
Notice: The proper pinion depth setting is a two-step procedure.
1. The setup dimension arrived at with the dial indicator is a starting point.
2. The gear tooth pattern check is necessary to "fine tune" the pinion depth and may indicate additional shim changes to the pinion stem.
Do both procedures in order to ensure the proper axle performance and to prevent system damage.
10. Install the differential and adjust the ring and pinion gear backlash. Refer to Backlash Adjustment.
11. For the initial backlash setting, move the ring gear from the pinion by subtracting 0.25 mm (0.010 in) from the ring gear side shim pack and adding 0.25 mm (0.010 in) to the shim pack on the opposite side.
12. In order to obtain the proper preload on the side bearings, add 0.10 mm (0.004 in) to the measurement of each shim pack.
Notice: The proper pinion depth setting is a two-step procedure.
1. The setup dimension arrived at with the dial indicator is a starting point.
2. The gear tooth pattern check is necessary to "fine tun& the pinion depth and may indicate additional shim changes to the pinion stem.
Do both procedures in order to ensure the proper axle performance and to prevent system damage.
13. Install the differential and adjust the ring and pinion gear backlash. Refer to Backlash Adjustment.
Pinion Installation
Installation Procedure
Tools Required
- J 5590 Rear Pinion Bearing Cone Installer
- J 23911 Pinion Oil Seal Installer
- J 8614-01 Pinion Flange Remover
1. Ensure that the bearing cups have been installed. For bearing cup installation, refer to Pinion Depth Adjustment.
2. Install the selective shim between the inner bearing and the shoulder on the gear.
3. Install the pinion bearing using the J 5590.
Drive the bearing on until the cone seats on the pinion shims.
4. Install a new collapsible spacer. Lubricate the pinion bearings using axle lubricant.
5. Install the pinion to the axle housing.
6. Install the outer pinion bearing onto the pinion using the J 5590. When you drive the bearing onto the pinion, hold the pinion forward from inside the case.
7. Install the pinion oil seal using the J 23911.
8. Install the pinion flange by tapping the flange using a soft-faced hammer until a few threads are shown.
9. Install the pinion washer and nut while holding the pinion flange using the J 8614-01.
10. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut in order to seat the bearings. When no end play is present in the pinion, check the preload torque.
11. Remove the J 8614-01. Check the pinion preload by rotating the pinion using an inch pound torque wrench. Preload should be at or below 2.7-3.6 N.m (24-32 lb in) on new bearings, or within 1.0- 1.4 N.m (8-12 lb in) for used bearings.
12. If the preload torque is below the specified values, continue torquing the nut in small increments. Check the preload after each tightening. Each tighten increases the bearing preload by several pounds. If the bearing preload is exceeded, remove the pinion, and install a new collapsible spacer.
13. Once the specified preload has been obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the preload, and adjust if necessary.
14. Install the differential case. Refer to Backlash Adjustment.
Backlash Adjustment
Adjustment Procedure
1. Install the differential case, the bearing cups, the spacers, and the shims as determined from the side bearing preload adjustment. Refer to Side Bearing Preload Adjustment.
2. Rotate the case several times in order to seat the bearings.
3. Using a magnetic base, install a dial indicator to the case.
4. Place the indicator stem at the heel end of a gear tooth.
5. Set the dial indicator so that the stem is in line with the gear rotation and perpendicular to the tooth angle.
6. Install the differential bearing caps and the bolts.
Tighten
Tighten the bolts to 75 N.m (55 lb ft).
7. Check and record the backlash at three or four points around the ring gear.
- When checking backlash, hold the pinion stationary.
- The backlash should be the same at each point within 0.05 mm (0.002 in). If the backlash varies more than 0.05 mm (0.002 in), check for the following conditions:
- Burrs
- A distorted case flange
- Uneven bolting
8. For all new gear sets, backlash at the minimum lash point measured should be 0.13-0.23 mm (0.005-0.009 in).
9. If the backlash is not within specifications, move the ring gear in or out from the pinion by increasing the thickness of one shim, and decreasing the thickness of the other shim an equal amount. This will maintain the correct axle side bearing preload.
Moving 0.05 mm (0.002 in) of shim from one side of the differential to the other will change the backlash adjustment by 0.03 mm (0.001 in).
10. When you have correctly adjusted the backlash, remove the bearing caps and the shim packs.
11. Select a shim 0.10 mm (0.004 in) thicker than the one removed from the left side. Insert this shim between the spacer and the left bearing race.
12. Install the left bearing cap and bolts. Do not tighten.
13. Select a shim 0.10 mm (0.004 in) thicker than the shim removed from the right side. Insert the shim between the spacer and the right bearing race. Drive the shim into place.
14. Install the right side bearing cap and bolts.
Tighten
Tighten the bolts to 75 N.m (55 lb ft).
15. Recheck the backlash. Correct as necessary.
Gear Tooth Contact Pattern Check
Before the final assembly of the differential, a gear tooth contact pattern check should be performed.
A gear tooth contact pattern check is NOT a substitute for adjusting the pinion depth and the backlash. The gear tooth contact pattern check is a final check in order to verify the correct running position of the ring gear and the drive pinion. Any gear sets which are not aligned properly may be noisy and have a short life. With a pattern check, the best contact between the ring gear and the drive pinion for low noise level and long life can be ensured.
Gear Tooth Terms
The side of the ring gear tooth which curves outward, or is convex, is the DRIVE side (4). The concave side is the COAST side (3). The end of the tooth nearest center of the ring gear is the TOE end (2). The end of the tooth farthest away from the center is the HEEL end (1). The toe end of the tooth is smaller than the heel end.
Test
1. Wipe the oil out of the carrier.
Carefully clean each tooth of the ring gear.
2. Apply gear making compound sparingly to all ring gear teeth using a medium stiff brush.
When properly used, the area of pinion tooth contact will be visible when hand load is applied.
3. Using a torque wrench, apply a load until a torque of 62 N.m (45 lb ft) is required to turn the pinion.
- A test that is made without loading the gears will not give a satisfactory pattern.
- Turn the companion flange with a wrench so that the ring gear rotates one full revolution.
- Then reverse the rotation so that the ring gear rotates one revolution in the opposite direction.
- Excessive turning of the ring gear is not recommended.
4. Observe the pattern on the ring gear teeth.
Adjustments Affecting Tooth Contact
There are two adjustments, backlash and pinion depth, which will affect the tooth contact pattern. The effects of the bearing preloads are not easily seen on hand loaded teeth pattern tests. Make the adjustments within specifications before proceeding with the backlash and the drive pinion adjustments.
Adjust the pinion depth and the backlash as necessary, in order to obtain the correct pattern.
The pinion depth is adjusted by increasing or decreasing the shim thickness between the pinion head and the inner race of the rear bearing. The shim is used in the differential in order to compensate for the manufacturing tolerances. Increasing the shim thickness will move the pinion closer to the centerline of the ring gear.
The backlash is adjusted by means of the side bearing adjusting sleeves which move the entire case and the ring gear assembly closer to, or farther from the drive pinion. The adjusting sleeves are also used in order to set side the bearing preload. In order to increase the backlash, turn the left sleeve in and turn the right sleeve out an identical amount. In order to decrease the backlash, turn the right sleeve in and turn the left sleeve out an identical amount.
The contact pattern must be centrally located up and down on the face of the ring gear teeth.
Drive Axle Final Assembly
Installation Procedure
Tools Required
- J 8092 Driver Handle
- J 23765 Axle Bearing Installer
- J 23771 Axle Shaft Seal Installer
- J 23911 Pinion Oil Seal Installer
1. Install the bearing with J 23765 and J 8092 until the tool bottoms out against the housing shoulder.
2. Lubricate the bearing with axle lubricant.
Important:
- Do not damage the oil seal (1).
- The splines at the end of the axle shalt must engage with the splines of the axle side gear.
3. Install the oil seal (1) using the J 23771 until the seal (1)is flush with the axle tube. Lubricate the seal lips using axle lubricant.
4. Install the axle shafts into the axle housing.
5. Install the Cycles if locks on the axle shaft.
Pull the axle shaft outward so the Cycles if lock seats in the counterbore of the axle side gear.
6. Install the pinion shaft through the case and the differential gears. Align the hole in the pinion shaft with the lock bolt hole.
7. Install the pinion shaft lock bolt.
Tighten
Tighten the lock bolt to 34 N.m (25 lb ft).
7. Install the cover gasket and cover.
Tighten
Tighten the cover bolts to 27 N.m (20 lb ft).
8. Fill the axle using new lubricant to a level within 9.5 mm (318 in) of the filler plug hole.
Tighten
Tighten the filler plug to 35 N.m (26 lb ft).