Pinion Depth Adjustment
^ Tools Required- J 8001 Dial Indicator Set
- J 23597-1 Pinion Setting Gauge Arbor
- J 23597-11 Pinion Setting Gauge Plate
- J 21777-40 Rear Pilot Washer
- J 21777-42 Front Pilot Washer
- J 21777-43 Stud Assembly-Bolt
- J 21777-45 Side Bearing Discs
Use a pinion setting gauge in order to measure differential drive pinion gear depth. The gauge provides a normal or zero pinion as a gauging reference.
1. Install J 21777-40, J 21777-42, J 21777-43, and J 21777-45.
2. Install J 23597-11.
3. Install J 21777-42 into the rear axle housing.
Notice: Refer to Fastener Notice in Service Precautions.
4. Install the drive pinion gear setting gauge nut into the rear axle housing.
^ Tighten the differential drive pinion gear setting gauge nut to 2.3 Nm (20 inch lbs.).
5. Rotate J 23597-11 in order to seat the following components:
^ The differential drive pinion gear outer bearing (2)
^ The differential drive pinion gear inner bearing (1)
6. Mount J 8001 onto J 23597- 1.
7. Preload the dial indicator against the plunger about 1.27 mm (0.050 inch).
8. Install J 21777-45 onto J 23597-11. Position this unit into the rear axle housing.
9. Install the following components:
^ The carrier bearing caps (3)
^ The bearing cap bolts/screws (2)
^ Tighten the differential carrier bearing cap bolt/screws (2) to 75 Nm (55 ft. lbs.).
10. Use the following steps in order to measure the differential drive pinion gear depth:
10.1. Rotate J 23597-1 slowly back and forth until J 8001 reads the greatest deflection. The deflection is the point where the needle changes direction.
10.2. At the point of deflection, set J 8001 to zero.
10.3. Repeat the rocking action in order to verify the zero setting.
10.4. After obtaining the zero setting, rotate J23597-1 until the plunger no longer touches J 23597-11.
This action provides the gauge reference of a zero or nominal drive pinion gear.
10.5. Use the following information in order to select the correct shim:
^ Record the J 8001 reading at the pointer position. The required drive pinion gear shim thickness is equal to the J 8001 reading.
For example, if the pointer moved counterclockwise 1.70 mm (0.067 inch) to a dial reading of 0.84 mm (0.033 inch), a shim thickness of 0.84 mm (0.033 inch) is required.
^ Drive pinion gear shims are available in 0.03 - 0.94 mm (0.001 - 0.037 inch).
The thickness of each shim is etched on the flat surface of the shim.
11. Loosen the J 21777-43.
12. Remove all of the special tools from the rear axle housing.
13. Remove the inner (1) and the outer (2) drive pinion gear bearings from the rear axle housing.
14. Install the correct drive pinion gear shim on the drive pinion gear.
15. Use the following steps in order to set the proper drive pinion gear depth:
15.1. Use the set-up dimension determined by J 8001 as a starting point.
15.2. Perform a ring gear tooth pattern test in order to fine tune the drive pinion gear depth.
The test may indicate additional necessary drive pinion gear shim changes.
Refer to Pinion and Ring Gear Inspection.
16. Install the following components:
^ The drive pinion gear inner bearing
^ The drive pinion gear outer bearing
Refer to Drive Pinion Assemble.
17. Assemble the differential case. Refer to Rear Axle - Assemble.
18. Measure the total preload at the drive pinion gear nut bearings.
The preload should measure within the following specifications:
^ With new inner and outer drive pinion gear bearings and a new drive pinion gear seal, the preload should measure 3.6 - 6.2 Nm (32 - 55 inch lbs.).
^ With used inner and outer drive pinion gear bearings and a new drive pinion gear seal, the preload should measure 1.8 - 3.1 Nm (16 - 28 inch lbs.) when rotating with a new drive pinion gear seal.