Drive Pinion Shim Selection

DRIVE PINION SHIM SELECTION

^ TOOLS REQUIRED
- J35664 Pinion Shaft Bearing Installer
- J44856 Pinion Depth Shim Selector
- J44861 Pinion Inner Bearing Race Installer
- J44864 Pinion Nut Wrench
- J44865 Spline Socket
- J44869 Assembly Holding Fixture

NOTICE: Inspect press bar surface. Do not press housing against a rough surface. The sealing surface could be damaged.





1. Using axle lube, lightly lubricate the bearing race. Place Pinion Inner Bearing Race Installer J44861 inside the race, using a press, install the race.
2. Inspect the race to ensure it is properly seated.

NOTICE: If dowel pins are still in the housing, remove them before pressing. Pressing on the dowel pins will damage the housing.





3. Using axle lube, lightly lubricate bearing race. Place Pinion Inner Bearing Race Installer J44861 inside the race, using a press, install the race.





4. Install Pinion Depth Shim Selector J44856 -2, -3, 4 on the pinion bearings (1).

IMPORTANT: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

IMPORTANT: Lightly lubricate the bearing rollers with axle lube.





5. Hold the shaft and tighten.
Torque:
Shaft Nut: 1.69 Nm (15 inch lbs.)





6. Rotate stud assembly while inspecting the rolling torque.





7. Turn housing over so that J44856-3 (1) pinion gage plate is up.
8. Install J44856-5 (2) master bearings on the J44856-1 (3) arbor and place it in the differential bearing bores.





9. Install retaining caps J44856-9 over the master bearings, using 2 (M:10) rear cover bolts and snug tighten bolts.





10. Install dial indicator on the arbor post.
11. Rotate J44856-1 so that the gage pin is not in contact with the J44856-3 gage block and zero the dial indicator.





12. Lift the gage pin and rotate the J44856-1. Drop the gage pin onto the J44856 3 pinion gage block.
13. Rock the arbor back; and forth slightly, record the maximum reading from the dial indicator.
Subtract this measurement from 2.54 mm (0.100 inch); this equals shim thickness.
14. Remove pinion shimming tools.





15. Using Pinion Shaft Bearing Installer J35664, position the pinion shaft (3) into a press. Install the determined shim (2) and bearing (1) on the shaft.





16. Install the pinion shaft (4), the new collapsible spacer (3), and the bearing (1) into the differential housing (2).

NOTICE: Do not over-press the bearing on the shaft, this could pre-crush the collapsible spacer.

IMPORTANT: The rear face of the pinion shaft must be supported in order to install the pinion shaft and bearing.





17. Position the pinion shaft and differential housing into a press in order to press the bearing on the shaft using Pinion Shaft Bearing Installer J35664.





18. Install the differential housing on the Assembly Holding Fixture J44869 using 4 clutch cover bolts (1). Attach the housing and fixture to a bench.

IMPORTANT: The pinion nut is left-hand threaded.





19. Install a new pinion nut on the pinion shaft. Place the Pinion Nut Wrench J44864 (1) over the pinion shaft (1). Turn the pinion shaft by hand to align the hex nut and the Pinion Nut Wrench J44864 to the flats of the Assembly Holding Fixture J44869 (2).





20. Place Spline Socket J44865 (1) and breaker bar over the splines on the pinion shaft.
21. Tighten the nut in the left-handed direction in small increments as needed to apply bearing preload.





22. Remove Pinion Nut Wrench J44864. Place the Spline Socket J44865 on a needle type torque wrench, rotate the shaft, inspecting the rolling torque.
Torque:
Shaft: 1.69 Nm (15 inch lbs.)





23. When the rolling torque is reached, use a punch to stake the nut on the pinion shaft flats.