Front Axle - C200F

PINION DEPTH-BEARING PRELOAD-GEAR BACKLASH

The pinion gear depth is adjusted with a select shim located under the rear pinion bearing cup. Differential bearing preload and backlash is adjusted with select snap rings.

PINION DEPTH MEASUREMENT





NOTE: Take measurement with pinion shim removed and rear bearing cup in place.

1. Assemble Pinion Height Block 6739 (3), Pinion Block 9534 (2), and rear pinion bearing (1) onto Screw 6741.
2. Insert assembled height gauge components, rear bearing and screw into housing through pinion bearing cups.
3. Install pinion front bearing and Cone-Nut 6740. Tighten Cone-Nut until Torque To Rotate screw is 3.4 Nm (30 in. lbs.).





4. Install Arbor Discs 9538 (1) into housing bearing bores.





5. Install Arbor Bar D-115-3 (1) through arbor discs.





6. Verify pinion depth setup is as shown.





7. Install Metric Dial Indicator 9524 (1) into Scooter Block D-115-2A (2) and secure with set screw (3).





8. Place Scooter Block with Dial Indicator on the pinion height block, so dial probe and scooter block is flush against the pinion height block (1). Hold scooter block in place and zero the dial indicator.





9. Slide the dial indicator (1) probe over the edge of the pinion height block and on to the arbor bar (2). With the scooter block against the pinion height block.
10. When dial probe contacts the arbor bar, the dial pointer will turn clockwise. Continue moving the dial indicator to the crest of the arbor bar and record the highest reading. Then add 4 mm (0.157 in.) to the recorded reading. This will be the correct pinion height shim selection.

DIFFERENTIAL SIDE BEARING PRELOAD





Differential side bearing preload is predetermined. The select snap rings in the differential housing provides differential side bearing preload. These snap rings can be adjusted to obtain the correct ring gear backlash measurement.

If differential case, bearings or housing are replaced the differential side bearing preload select snap rings must be determined. Preload measurement is performed with Dummy Bearings 9905 and Dummy Snap Rings 9904. Each dummy snap ring is 3 mm (0.118 in) thick which must be added to the measurement.

1. Install differential case without differential bearings into the housing.
2. Install Dummy Bearings 9905 into the housing and onto the differential case.
3. Install Dummy Snap Rings 9904 (1) into the differential housing (2) snap ring grooves.





4. Install Dial Indicator 9524 (2) on the housing and position indicator plunger between the ring gear bolts (1).





5. Push and hold differential case (1) to the pinion gear side of the housing, then zero the dial indicator (2).





6. Push and hold differential case (1) to the ring gear side of the housing, and record differential dial indicator (2) reading.
7. Add differential dial indicator (2) reading to dummy snap rings thickness 6 mm (0.236 in). Add this to differential bearing preload 0.13 - 0.19 mm (0.005 - 0.007 in). This is the total thickness of both select snap rings needed for differential side bearing preload.
EXAMPLE: Differential Dial Indicator Reading + Dummy Snap Rings 6 mm (0.236 in.) + Preload Specification 0.13 - 0.19 mm (0.005 - 0.007 in.) = Total Differential Snap Rings Thickness





8. Remove the differential case.
9. Install the pinion and establish pinion Torque To Rotate.
10. Install differential case without differential bearings into the housing.
11. Install Dummy Bearings 9905 into the housing and onto the differential case.
12. Install Dummy Snap Rings 9904 (1) into the differential housing (2) snap ring grooves.





13. Install Dial Indicator 9524 (2) on the housing and position indicator plunger between the ring gear bolts (1).





14. Push and hold differential case (1) to the pinion gear, then zero the dial indicator (2).





15. Push and hold differential case (1) to the ring gear side of the housing, and record ring gear dial indicator (2) reading.
16. Add dummy snap ring 3 mm (0.118 in.) to recorded ring gear dial indicator (2) reading, then subtract 0.05 mm (0.002 in) for backlash. This is the select snap ring thickness needed on the ring gear side of the differential case.
EXAMPLE: Ring Gear Dial Indicator Reading + Dummy Snap Ring 3 mm (0.118 in.) - Backlash Specification 0.05 mm (0.002 in.) = Ring Gear Side Snap Ring

17. Subtract ring gear side select snap ring thickness from the total snap ring thickness. This is the select snap ring thickness needed on the pinion gear side of the differential case.
EXAMPLE : Total Differential Snap Ring Thickness - Ring Gear Side Snap Ring = Pinion Gear Side Snap Ring

RING GEAR BACKLASH MEASUREMENT





NOTE: If Spreader W-129-B is installed, make sure tension on axle housing is relieved.

1. Install differential into the housing.
2. Set up Dial Indicator Set C-3339A with Clamp SP-5426 (1), Post SP-5425-B (2) and Metric Dial Indicator 9524 (3) to measure ring gear backlash:
3. Rotate ring gear one direction to take up clearance to pinion. Verify indicator tip is in contact with ring gear and zero indicator. Rotate ring gear back and forth and record measurement. Ring gear backlash should be 0.13-0.25 mm (0.005-0.009 in.). Verify backlash measurement in four (4) positions.





4. If backlash measurement is less than 0.13 mm (0.005 in), it is necessary to decrease the snap ring thickness on the ring gear side, and increase the thickness on the pinion side equal amounts.
5. If backlash measurement is greater than 0.25 mm (0.009 in), it is necessary to increase the snap ring thickness on the ring gear side, and decrease the thickness on the pinion side equal amounts.

GEAR CONTACT PATTERN

The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.

1. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth.
2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern.
3. With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.

The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash as necessary.




Gear Tooth Contact Patterns