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SECTION 2 - PROCEDURES
that 0.003 inches (0.076 mm) more shims be added than if
the pinion were etched "0". By adding 0.003 inches (0.076
mm) shims, the mounting distance of the pinion was
decreased to 2.622 inches (66.599 mm), which is just
what a -3 etching indicated.
10. If the old ring and pinion set are to be reused, mea-
sure the old shim pack and build a new shim pack to
the same dimension. If a baffle is in the axle assem-
bly, it is considered as part of the shim pack. To
change the pinion adjustment, shims are available in
thicknesses of 0.003 inches (0.076 mm), 0.005
inches (0.127 mm), and 0.010 inches (0.254 mm).
NOTE: If a baffle or slinger is bent or mutilated, it should be
replaced.
11. Measure each shim separately with a micrometer
and add together to get total shim pack thickness
from original build up.
12. If a new gear set is being used, notice the (+) or (-)
etching on both the old and new pinion and adjust
the thickness of the new shim pack to compensate
for the difference of these two figures.
For example: If the old pinion reads (+) 2 and the new pin-
ion is (-) 2, add 0.004 inches (0.102 mm) shims to the orig-
inal shim pack.
NOTE: Use large diameter master bearing discs for this
axle.
Be sure that all carrier bores are free from all nicks,
dirt, or any other contamination.
13. Place the master pinion block (Dana part no. D-139
or equivalent) into the pinion bore of the carrier.
14. Place arbor discs (Dana part no. D-115-4 or equiva-
lent) and arbor (Dana part no. D-115-3 or equivalent)
into the cross bores of the carrier.
15. Place a pinion height block (Dana part no. D-115-1
or equivalent) on top of the master pinion block, and
against the arbor block.
16. Place a scooter gage (Dana part no. D-115) on the
small step of the pinion height block. Apply finger
pressure, making sure the gage is flat on the pinion
height block. While pressure is applied, set indicator
to zero (0).
17. Slide the scooter gage over the arbor. As the gage
slides over top the arbor, it will travel in a clockwise
direction. When the indicator is on the center of the
arbor (on top), it will stop traveling in a clockwise
direction. If the indicator starts to travel in a counter-
clockwise direction, this means that the center (top)
of the arbor has been passed. Record only the read-
ing when the indicator is at the highest point. This
reading indicates the amount of shims necessary to
2-20
obtain the correct shim pack, plus (+) or minus (-)
the etching on the bottom end of the pinion. If the
etching is zero (0), the shim pack will remain
unchanged.
For example: If a pinion is etched "+3", this pinion would
require 0.003 inches (0.076 mm) less shims than a pinion
etched zero (0). If a pinion is etched "-3", it will be neces-
sary 0.003 inches (0.076 mm) more shims than would be
required if the pinion were etched zero (0).
18. Measure each shim separately with a micrometer
and add together to get the total shim pack thick-
ness. If a baffle is required, it is to be included in the
shim pack. If a slinger is used between the inner
bearing cone and the thrust face of the pinion, the
slinger is also to be measured and included as a
part of the total shim pack.
19. Place the required amount of shims (and baffle if
used) in the inner bearing bore; drive the inner bear-
ing cup into the carrier using a cup installer and han-
dle (Dana part nos. D-145 and C-4171, respectively,
or equivalent).
20. Assemble the outer pinion bearing cup into the car-
rier using a cup installer and handle as in step 23.
21. Assemble the inner bearing cone (and slinger if
used) on the pinion, then place the bearing installer
(Dana part no. W-262 or equivalent) over the pinion
shaft. Drive the bearing on the shaft until it is com-
pletely seated.
22. Assemble preload shims (which were removed dur-
ing disassembly) onto pinion. Assemble bearing
cone and slinger.
23. Apply a light coat of hypoid lubricant to the lip of the
pinion seal and assemble into the housing using a
seal installer and handle (Dana part nos. W-147D
and C-4171, respectively, or equivalent).
24. Using a suitable yoke holder (Dana part no. C-3281
or equivalent), assemble end yoke, washer and pin-
ion nut. Torque pinion nut to 200-220 ft. lb. (271-298
Nm) using a suitable torque wrench (Dana part no.
C-4053 or equivalent).
25. Using a torque wrench calibrated in inch lb., rotate
the pinion. Pinion torque should be 20-40 in. lb. (2.3-
4.5 Nm). To increase preload, remove shims; to
decrease preload, add shims.
– JLG Sizzor –
3120791
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