Assembly of Components
Assemble in the order shown in the illustration, referring to the following notes:
Oil baffle, bearing outer race and bearing inner race (1, 2, 3)
NOTE: The oil baffle. bearing outer race and bearing inner race were installed during the oil slinger is elective shim thickness check.
Oil Slinger/Selective Shim, Drive Pinion And Rear Bearing (4, 5, 6)
1. Install the oil slinger/selective shim on the drive pinion.
2. On Dana 35 Axles install the rear bearing using a press and the SSTs.
3. On Dana 28 Axles install the rear bearing using a press, the SST and Pinion Bearing Replacer T57L-4621-B, or equivalent.
Collapsible Spacer (7)
CAUTION: Never reuse a collapsible spacer. It must be replaced when it is removed.
Oil Seal (10)
1. Apply gear lubricant to the oil seal.
2. On Dana 35 Axles install the oil seal using Pinion Oil Seal Replacer T79P-4676-A. or equivalent.
3. On Dana 28 Axles install the oil seal using Pinion Oil Seal Replacer T9OT-4676-A. or equivalent.
NOTE: Make sure the spring does not pop out of the seal. Replace the seal if the spring pops out.
Companion Flange (11)
1. Install the dust shield onto the companion flange.
2. On Dana 35 Axles install the companion flange using Companion Flange Replacer T85T-4851-AH, or equivalent and tighten to 271 Nm (200 ft. lbs.).
3. On Dana 28 Axles install the companion flange using Companion Flange Replacer T83T-4851-A, or equivalent and tighten to 271 Nm (200 ft. lbs.).
4. Check the rotational torque of the drive pinion. Rotational torque should be within 1.7 - 2.8 Nm (15 - 25 inch lbs.).
NOTE: If rotational torque exceeds 2.8 Nm (25 inch lbs.) the collapsible spacer must be replaced.
5. If rotational torque is not within 1.7 - 2.8 Nm (15 - 25 inch lbs.), tighten the locknut until it is within 1.7 - 2.8 Nm (15 - 25 inch lbs.).
CAUTION: Never tighten the locknut more than 474 Nm (350 ft. lbs.), or the collapsible spacer will need to be replaced.
Pinion Gears And Thrust Washers (13)
1. Hold the side gears with one hand and install the pinion gears and thrust washers.
2. Rotate the side gears and pinion gears until the holes in the pinion gears align with the hole for the pinion shaft.
Pinion Shaft (14)
1. Drive the pinion shaft into the gear case until the lockpin hole in the pinion shaft aligns with the hole in the gear case.
2. Drive the new lockpin into the gear case. After installing the new lockpin. make a crimp so that it cannot come out of the gear case.
Ring Gear (16)
^ Tighten ring gear to 95 - 122 Nm (70 - 90 ft. lbs.).
Differential Gear Assembly And Shims (17, 18)
1. Install the differential gear assembly into the differential casing with the SSTs (Dana 35) or Dummy Bearings T83T-4222-A, or equivalent or the original bearing (Dana 28) still attached.
2. Mount a dial indicator on the differential casing.
3. Press the gear case as far as it will go toward the dial indicator and zero the dial indicator.
4. Force the ring gear against the pinion gear. rocking the ring gear to make sure the teeth are in contact.
5. Press the gear case as far as it will go away from the dial indicator.
6. Repeat this procedure until the same reading is obtained. Record the measurement (B).
7. Subtract measurement B (above) from measurement A to calculate the clearance opposite the ring gear. This is measurement C.
8. Remove the differential gear assembly from the differential casing.
9. Assemble the ring gear side shim pack by subtracting 0.13 mm (0.005 inch) from measurement B.
10. Assemble the shim pack for the opposite side of the ring gear by adding 0.25 mm (0.010 inch) to measurement C.
NOTE:
^ On Dana 28 axles, the shims will be installed on the gear case prior to installing the side bearings.
^ On Dana 35 axles, the shims will be installed into the differential casing prior to installing the gear case into the differential casing.
^ Dana 35 axles use outboard selective spacers.
Side Bearings (19)
1. On Dana 28 Axles, Install The Side Bearings As Follows:
a. Install the required amount of shims and the side bearings onto the opposite side of the ring gear.
b. Install the side bearings using a press, the SSTs and Differential Side Bearing Replacer T85M-4221-A, or equivalent.
c. Install the required amount of shims and the side bearings onto the ring gear side.
d. Install the side bearings on the ring gear side using a press and Differential Side Bearing Replacer T85M4221-A or equivalent and the SST. Place the SST on the ring gear side to prevent damage.
2. On Dana 35 Axles, Install The Side Bearings As Follows:
a. Install the side bearings using the SSTs.
b. Install the side bearings on the ring gear side using the SSTs.
Differential Casing (21)
1. Install the SST.
2. Attach dial indicator to the SST.
3. Spread the differential casing.
NOTE: Do not spread the differential casing over 0.25 mm (0.010 inch).
4. Install the differential gear assembly into the differential casing.
NOTE:
^ If necessary, use a plastic hammer to install the differential gear assembly into the differential casing.
^ Do not nick the teeth on the ring gear or the pinion gear.
Bearing Cap (22)
1. Install the bearing caps, referring to the location note made during disassembly. Tightening torques:
^ Dana 28: 41 - 61 Nm (30 - 45 ft. lbs.)
^ Dana 35: 64 - 91 Nm (47 - 67 ft. lbs.)
2. Check the ring gear and pinion backlash at three spots on the ring gear. Standard backlash should be within 0.13 - 0.20 mm (0.005 - 0.008 inch).
NOTE:
^ The backlash readings should not vary by more than 0.08 mm (0.003 inch).
^ If the backlash is high, move shims to the ring gear side from the opposite of the ring gear side to move the ring gear toward the drive pinion.
^ If backlash is low, move shims to the opposite side of the ring gear from the ring gear side to move the ring gear away from the drive pinion.
3. The inspection and adjustment procedure is as follows:
a. Coat both surfaces of 6 - 8 teeth of the ring gear uniformly with a thin coat of red lead.
b. While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact.
c. If the tooth contact is correct, wipe off the coating of red lead.
d. If it is not correct, adjust the pinion height and then the backlash.
e. Toe-and-flank contact Replace the oil slinger/selective shim with a thinner one, and move the drive pinion outward.
f. Heel-and-face contact Replace the oil slinger/selective shim with a thicker one, and bring the drive pinion in closer.