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FRONT SUSPENSION
2 - 37
I f r e p l a c e m e n t g e a r s a n d t h r u s t w a s h e r s w e r e
i n s t a l l e d , i t i s n o t n e c e s s a r y t o m e a s u r e t h e g e a r
" b a c k l a s h " . T h e g e a r m e s h i n g w i l l b e c o r r e c t be-
c a u s e " c l o s e " m a c h i n i n g t o l e r a n c e s
a r e u s e d
d u r i n g m a n u f a c t u r e o f t h e g e a r s .
(4) Position t h e r i n g gear o n t h e differential case
flange a n d a l i g n t h e r i n g gear threaded holes w i t h
those i n the differential case flange (Fig. 37).
(5) Insert r e p l a c e m e n t
r i n g gear bolts ( F i g . 37)
t h r o u g h the differential case flange a n d t h r e a d t h e m
i n t o the r i n g gear.
A f t e r
a l l t h e b o l t s
a r e i n i t i a l l y
c o r r e c t l y
t h r e a d e d i n t o t h e r i n g g e a r b o l t h o l e s , " t a p " t h e
r i n g g e a r w i t h a n o n - m e t a l l i c m a l l e t a n d e n s u r e
t h a t i t i s f l u s h a g a i n s t t h e f l a n g e .
(6) Clamp t h e differential case i n a vise equipped
w i t h soft jaws and alternately t i g h t e n each r i n g gear
bolt w i t h 61-81 N*m (45-60 ft-lbs) torque.
(7) Place Master D i f f e r e n t i a l B e a r i n g Tools D-135
on the differential case hubs (Fig. 41).
MASTER BEARING
MASTER BEARING
RY652
Fig. 41 Master Bearing Tools On Hubs
(8) Position Spreader Tool W-129-A on the differen-
t i a l housing w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 42). I n s t a l l the holddown clamps
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(9) I n s t a l l a p i l o t stud a t t h e left side o f t h e differ-
e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
the differential housing ( v i a the p i l o t stud) w i t h the
indicator plunger s l i g h t l y "loaded" against the oppo-
site side of the differential housing (Fig. 42). "Zero"
the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
TOOL
C-3339
RH411A
Fig. 42 Differential Housing Separation
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(10) Tighten the spreader tool t u r n b u c k l e (Fig. 42)
and separate the differential housing only enough t o
i n s t a l l the differential case i n the housing. S e p a r a t e
t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m d i s t a n c e o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure t h e separation distance w i t h the d i a l indicator
(Fig. 42) as the housing is being separated.
(11) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 42) when the differential housing has been
separated sufficiently to i n s t a l l t h e differential case
i n the housing.
(12) I n s t a l l the differential case i n the differential
housing.
(13) Remove the holddown clamps and the spreader
tool from the differential housing (Fig. 42).
(14) Observe the assembly reference marks and po-
sition t h e bearing caps a t t h e i r o r i g i n a l locations.
T i g h t e n the bearing cap bolts " f i n g e r - t i g h t " .
(15) I n s t a l l a p i l o t stud a t the r i g h t side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e pilot stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
back of the r i n g gear (Fig. 43), —
(16) Insert a small p r y bar between the bearing cap
and the left side o f t h e differential case. P r y the dif-
ferential case as far as possible toward the r i g h t side
of the differential housing (Fig. 43). "Zero" t h e d i a l
indicator pointer.
(17) Pry the differential case t o w a r d the left side of
the housing w i t h t h e pry bar and r e c o r d the t r a v e l
distance indicated b y the d i a l indicator pointer.
T h e
m e a s u r e m e n t
a b o v e i n d i c a t e s
t h e s h i m
t h i c k n e s s n e c e s s a r y f o r d i f f e r e n t i a l case " z e r o "
" e n d - p l a y " (i.e., t o e l i m i n a t e t h e space/gap t h a t
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