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not contacting the p i n i o n gear m a t e shaft, the side
gear clearance is acceptable.
(4) I f a side gear clearance is more t h a n 0.005 i n c h
(and the axle shaft is not contacting the differential
pinion gear m a t e shaft), record t h e side gear clear-
ance. Remove the t h r u s t washer and measure i t s
thickness w i t h a micrometer. A d d the washer t h i c k -
ness to the recorded side gear clearance. The sum of
the gear clearance and t h e washer thickness w i l l de-
termine the r e q u i r e d thickness of the replacement
t h r u s t washer.
F o r e x a m p l e , i f t h e s i d e g e a r c l e a r a n c e is 0.007
i n c h a n d t h e t h r u s t w a s h e r t h i c k n e s s i s 0.033
i n c h , t h e s u m i s 0.04 i n c h . I n s t a l l t h e " t h i c k e s t "
t h r u s t w a s h e r f r o m t h e s e r v i c e p a c k a g e
t h a t
does n o t e x c e e d t h e s u m c a l c u l a t e d a b o v e . I n
t h e e x a m p l e s i t u a t i o n , a 0 . 0 3 7 - i n c h t h i c k w a s h e r
f r o m t h e s e r v i c e p a c k a g e s h o u l d b e i n s t a l l e d be-
cause t h e n e x t l a r g e r w a s h e r size i s 0.042-inch
t h i c k , w h i c h w o u l d b e t o o t h i c k . W h e n t h e r e -
p l a c e m e n t t h r u s t w a s h e r i s i n s t a l l e d , t h e side
g e a r c l e a r a n c e s h o u l d b e 0.003 i n c h .
(5) I n some instances, the end of the axle shaft w i l l
move and contact the p i n i o n gear mate shaft w h e n
the feeler gauge blades are inserted behind the side
gear. W h e n t h i s occurs, the C-clip " l o c k " on the axle
shaft is p r e v e n t i n g the side gear f r o m s l i d i n g on the
axle shaft a n d m o v i n g independently i n w a r d .
T o
d e t e r m i n e t h e t o t a l s i d e g e a r
c l e a r a n c e
w i t h t h i s s i t u a t i o n (above), r e - m e a s u r e t h e c l e a r -
a n c e w d t h t h e C - c l i p " l o c k " r e m o v e d . C o m p a r e
t h i s m e a s u r e m e n t w i t h t h e m e a s u r e m e n t w h e n
t h e C-clip " l o c k " w a s i n s t a l l e d .
(6) Remove the C-clip " l o c k " f r o m the axle shaft(s)
t h a t have no "end play". W i t h t h e differential case
disassembled, use a micrometer to measure the
t h r u s t washer thickness. Record the thickness and
r e t u r n the t h r u s t washer behind the side gear. As-
semble the differential case w i t h o u t the C-clip " l o c k "
installed and re-measure the side gear clearance.
(7) Compare the clearances. I f t h e clearance differ-
ence is less t h a n 0.012 inch, add the side gear clear-
ance recorded w h e n the C-clip " l o c k " was installed to
the t h r u s t washer thickness measured w i t h the m i -
crometer. The s u m w i l l determine the required thick-
ness of the replacement t h r u s t washer.
F o r e x a m p l e , i f t h e s i d e g e a r c l e a r a n c e i s 0.006
i n c h w i t h t h e a x l e s h a f t C - c l i p " l o c k " i n s t a l l e d
a n d 0.015 i n c h w i t h t h e C - c l i p " l o c k " r e m o v e d ,
t h e d i f f e r e n c e i s 0.009 i n c h , w h i c h is less t h a n
0.012 i n c h . A d d 0.006 i n c h ( t h e c l e a r a n c e
w i t h
t h e C - c l i p " l o c k " i n s t a l l e d ) t o t h e t h r u s t w a s h e r
t h i c k n e s s (e.g., 0.032 i n c h ) . T h e s u m is 0.038 i n c h .
T h e c l o s e s t t h r u s t w a s h e r t h i c k n e s s t h a t does
n o t e x c e e d 0.038 i n c h i s 0.037 i n c h .
(8) I f the clearance difference is 0.012 inch or
greater, both side gears must be replaced ("matched
set") a n d t h e clearance measurements repeated.
(9) I f t h e side gear clearance difference (above) con-
tinues to be 0.012 i n c h or greater w i t h replacement
side gears and the " t h i c k e s t " t h r u s t washers from the
service package installed, the differential case m u s t
be replaced.
RING GEAR TEETH CONTACT
PATTERNS
(1) A p p l y a t h i n coat of H y d r a t e d Ferric Oxide
(commonly referred to as Yellow Oxide of Iron), or an
equivalent product, to both the " d r i v e " side and the
"coast" side of the r i n g gear teeth.
(2) Rotate t h e r i n g gear one complete r e v o l u t i o n i n
both directions w h i l e a load is being applied w i t h a
r o u n d bar or screwdriver inserted between the differ-
e n t i a l h o u s i n g and t h e differential case flange. This
action w i l l produce a distinct contact pattern on both
the " d r i v e " side and t h e "coast" side of the r i n g gear
teeth.
T h e g e a r t e e t h c o n t a c t p a t t e r n w i l l
d i s c l o s e
w h e t h e r o r n o t t h e d r i v e p i n i o n gear s h a f t r e a r
b e a r i n g d e p t h s h i m h a s t h e c o r r e c t t h i c k n e s s
a n d w h e t h e r o r n o t t h e r i n g g e a r " b a c k l a s h " h a s
b e e n
a d j u s t e d c o r r e c t l y . T h e
" b a c k l a s h " be-
t w e e n 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
m u s t b e m a i n t a i n e d w i t h i n t h e s p e c i f i e d l i m i t s
u n t i l t h e c o r r e c t t e e t h c o n t a c t p a t t e r n is o b -
t a i n e d .
(3) E x a m i n e the contact patterns on the r i n g gear
teeth and compare t h e m w i t h those i n Figs. 39
t h r o u g h 43 to determine i f the patterns are correct.
W i t h the d r i v e p i n i o n gear depth of mesh correct and
the r i n g gear " b a c k l a s h " adjusted correctly, the teeth
contact patterns should closely resemble the patterns
i l l u s t r a t e d i n F i g . 39. Notice t h a t the i l l u s t r a t e d
teeth contact patterns are w e l l centered on both the
" d r i v e " side and the "coast" side of the teeth.
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