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face of drive p i n i o n g e a r m u s t b e m e a s u r e d a n d
the
t h i c k n e s s i n c l u d e d
w i t h
t h e total
s h i m
" p a c k " t h i c k n e s s .
(7) Remove the measurement tools f r o m the differ-
e n t i a l housing.
(8) Place t h e depth shims i n t o t h e d r i v e p i n i o n gear
shaft rear bearing bore i n t h e differential housing
and t h e n force t h e rear b e a r i n g cup i n t o t h e bore
w i t h B e a r i n g Gup I n s t a l l a t i o n Tool D-111 (for Model
60 and 6 0 M axles) or Tool C-4204 (for Model 70 ax-
les) and D r i v e r Handle Tool C-4171. Ensure t h a t the
cup is correctly "seated".
(9) Use B e a r i n g Cup I n s t a l l a t i o n Tool C-4203 and
D r i v e r Handle Tool C-4171 t o force t h e drive p i n i o n
gear shaft front bearing cup i n t o t h e differential
housing bore (Fig. 26).
BEARING CUP
DRIVER
INSTALLATION TOOLC^203
HANDLE
Fig. 26 Shaft Front Bearing Cup Installation
(10) Force t h e rear b e a r i n g onto t h e drive p i n i o n
gear shaft u n t i l i t is completely "seated" w i t h Bear-
i n g I n s t a l l a t i o n Tool C-3095-A (Fig. 27).
(11) I n s t a l l the drive p i n i o n gear shaft i n the dif-
ferential housing.
(12) I n s t a l l the drive p i n i o n gear shaft front bear-
ing, oil slinger, (axle) yoke, washer and n u t . Use I n -
stallation Tool C-3718
a n d H o l d i n g Tool 3281 t o
i n s t a l l the yoke (Fig. 28).
D o not i n s t a l l the b e a r i n g
" p r e l o a d "
torque
shims o r the d r i v e p i n i o n g e a r shaft s e a l a t t h i s
time.
(13) "Seat" t h e shaft bearings b y t i g h t e n i n g t h e
(axle) yoke n u t u n t i l i t requires 1 N
#
m (10 in-lbs)
torque to rotate the drive p i n i o n gear shaft (Fig. 29).
Use a Newton-meter or a n inch-pound torque wrench
to measure the torque.
(14) Measure the drive p i n i o n gear depth o f mesh
( w i t h the r i n g gear). Place t h e p i n i o n height block
tool on t h e face of the d r i v e p i n i o n gear (Fig. 22).
Place t h e arbor and disc tools i n t o t h e differential
bearing cradles i n the differential housing (Fig. 23).
Place t h e gauge block tool w i t h t h e d i a l indicator
PINION GEAR
Fig. 27 Shaft Rear Bearing Installation
Fig. 28 Drive Pinion Gear Shaft (Axle) Yoke
Installation
tool o n t h e lowest step o f the p i n i o n height block
tool. E n s u r e t h a t t h e gauge block tool is resting
firmly
on t h e lowest step o f the p i n i o n height block
tool a n d "zero" t h e d i a l indicator pointer.
(15) W i t h t h e d i a l indicator pointer "zeroed", move
the gauge block tool t o w a r d the arbor tool u n t i l the
t i p o f t h e d i a l indicator plunger contacts the arbor
tool (Fig. 25). Slide the gauge block tool ( w i t h t h e
d i a l indicator) across and back and forth along t h e
arbor tool w h i l e observing the d i a l indicator pointer.
Record t h e longest plunger t r a v e l distance (whether
i n w a r d or o u t w a r d ) indicated by the pointer.
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