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2 - 66
FRONT SUSPENSION
•
• the drive p i n i o n gear shaft outer (front) and i n n e r
(rear) bearing cup bores i n t h e differential housing
should be smooth; a n d
• i f i t exists, raised m e t a l o n 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 hand stone.
(4)
E x a m i n e
t h e differential
pinion gear
mate
shaft, p i n i o n gears, side gears and t h r u s t washers
(Fig. 25) for wear a n d 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
a s 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 and t h e drive p i n i o n
gear shaft (Fig. 25) for excessively w o r n and chipped
teeth. E x a m i n e the r i n g gear for damaged a t t a c h i n g
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 d r i v e p i n i o n gear shaft (axle) yoke
(Fig. 25) for cracks, w o r n splines, " p i t t e d " areas, and
a rough/corroded seal contact surface. Repair or r e -
place the yoke as necessary.
(7) Inspect the drive p i n i o n gear shaft bearing "pre-
load" torque shims (Fig. 25) for cracks, damage a n d
distortion. I n s t a l l replacement
shims ( i f necessary)
for the "preload" 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 a n d 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 t h e differential case (Fig. 25).
(3) A l i g n the 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. 25).
Insert a n d "seat" t h e lock p i n i n the case and t h e
shaft.
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 b e -
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 gears.
(4) Position t h e r i n g gear o n t h e differential case
flange and 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. 25).
(5) Insert r e p l a c e m e n t
r i n g gear bolts (Fig. 25)
t h r o u g h the differential case flange and thread 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 holes, " 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) C l a m p t h e differential case i n a vise equipped
w i t h soft j a w s and alternately t i g h t e n each r i n g gear
bolt w i t h 110 N*m (81 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-117
on the differential case hubs (Fig. 28).
MASTER BEARING
MASTER BEARING
RY652
Fig. 28 Master Bearing Tools On Hubs
(8) Position Spreader Tool W-129-A on t h e differen-
t i a l housing w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 29). 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 " .
TOOL W-129-A*
TOOL C-3339
RH437
Fig. 29 Differential Housing Separation
(9) I n s t a l l a pilot 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 (via the pilot stud) w i t h t h e
indicator plunger s l i g h t l y "loaded" against the oppo-
site side o f the differential housing (Fig. 29). "Zero"
the d i a l indicator pointer.
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