Pinion Gear Mate Shaft Lock Pin Removal; Differential Bearing Removal - Dodge D150 1990 Service Manual

2 - 36 FRONT SUSPENSION •
DIFFERENTIAL
( w i t h hub i d e n t i t y ) for assembly reference. Record
the thickness o f the shims.
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
(Fig. 37) w i t h a n appropriate cleaning solvent and,
w i t h t h e exception o f t h e bearings, d r y w i t h com-
pressed air.
D o n o t s t e a m c l e a n t h e d i f f e r e n t i a l c o m p o -
n e n t s .
(2) To clean t h e axle shaft tubes, insert a stiff w i r e
into each tube, attach a clean cloth t o t h e w i r e a t the
differential housing opening and w i t h d r a w t h e w i r e
(and cloth) f r o m t h e housing o u t w a r d t h r o u g h t h e
tube.
(3) Inspect t h e differential bearings and t h e drive
p i n i o n gear shaft bearings, and the differential case
and housing (Fig. 37):
• the d i f f e r e n t i a l bearings a n d the drive p i n i o n gear
shaft f r o n t and rear bearings and cups should have a
smooth appearance w i t h no broken/dented surfaces
on the b e a r i n g rollers or t h e roller contact surfaces;
• the b e a r i n g races m u s t n o t be distorted or cracked;
I f a d i f f e r e n t i a l b e a r i n g m u s t b e r e p l a c e d , t h e
c u p a n d t h e b e a r i n g m u s t b e r e p l a c e d as a
" m a t c h e d s e t " o n l y .
• a l l t h e machined contact surfaces i n t h e differen-
t i a l housing a n d on t h e differential bearing caps
should be smooth and w i t h o u t any raised edges;
• the drive p i n i o n gear shaft front and rear bearing
cup bores i n t h e differential housing should be
smooth; and
• i f i t exists, raised m e t a l on t h e shoulders o f the
bearing cup bores i n c u r r e d d u r i n g removal o f t h e
cups should be removed w i t h a h a n d stone.
(4) E x a m i n e t h e differential p i n i o n gear mate
shaft, p i n i o n gears, side gears a n d t h r u s t washers
(Fig. 37) for wear and damage. Replace a l l defective
components.
I f e i t h e r o f t h e d i f f e r e n t i a l p i n i o n g e a r s i s n o t
r e u s a b l e , b o t h g e a r s m u s t b e r e p l a c e d as a
" m a t c h e d s e t " o n l y . D o n o t r e p l a c e o n l y o n e
g e a r .
(5) E x a m i n e t h e r i n g gear a n d t h e drive p i n i o n
gear shaft (Fig. 37) for excessively w o r n and chipped
teeth. E x a m i n e t h e r i n g gear for damaged bolt
threads.
I f r e p l a c e m e n t o f e i t h e r g e a r i s n e c e s s a r y , b o t h
t h e r i n g g e a r a n d t h e d r i v e p i n i o n g e a r s h a f t
m u s t b e r e p l a c e d b e c a u s e t h e y a r e a v a i l a b l e as
a " m a t c h e d s e t " o n l y .
(6) Inspect t h e drive p i n i o n gear shaft (axle) yoke
(Fig. 37) for cracks, excessively w o r n splines, " p i t t e d "
areas, and a rough/corroded seal contact surface. Re-
p a i r or replace the yoke as necessary.
(7) Inspect t h e drive p i n i o n gear shaft bearing "pre-
load" torque shims (Fig. 37) for cracks, damage and
distortion. I n s t a l l replacement shims ( i f necessary)
for the " p r e l o a d " torque adjustment.
ASSEMBLY
(1) L u b r i c a t e a l l t h e differential components w i t h
hypoid gear l u b r i c a n t .
(2) I n s t a l l t h e differential side gears and t h r u s t
washers, p i n i o n gears and t h r u s t washers and p i n i o n
gear mate shaft i n the differential case (Fig. 37).
(3) A l i g n t h e lock p i n hole i n the p i n i o n gear mate
shaft w i t h the hole i n the differential case (Fig. 37).
Insert a n d "seat" t h e lock p i n i n t h e case a n d t h e
shaft.