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REAR AXLE
3-9
(9) Inspect the drive gear for worn or chipped
teeth or damaged attaching bolt threads. If replace-
ment of the drive gear is necessary, replace both the
drive gear and drive pinion as they are furnished only
in matched sets.
(10) Inspect the drive pinion bearing cones and the
cups which may have been left in the carrier for pit-
ting, excessive wear, or other visible damage. If in-
spection reveals that they are unfit for further serv-
ice, replace the cup and the cone.
(11) Inspect the differential carrier for cracks or
other visible damage which would render it unfit for
further service. Raised metal on shoulders incurred
in removing pinion cups should be flattened by the use
of a flat nose punch.
(12) Inspect the drive pinion for damaged or ex-
cessively worn teeth, damaged bearing journals or
splines. If replacement of the pinion is necessary, a
new drive gear must also be used as they are fur-
nished only in matched sets. Also inspect the pinion
bearing spacer (where used) for distortion and dam-
age.
(13) Inspect the companion flange for cracks, worn
splines, pitted, rough or corroded oil seal contacting
surface. Repair or replace the companion flange as
Plymouth 10758 Rear Axle Group 3 21 pica Opr. G
necessary.
(14) Inspect the pinion bearing shim pack for dam-
aged or distorted shims. Replace the shims with cor-
rect ones during the establishment of the pinion bear-
ing preload.
ASSEMBLY
Differential Assembly
(1) Install the thrust washer on each of the differ-
ential side gears and position the gears in the case.
(2) Through the large side opening of the case, in-
sert each of the two pinions and thrust washers ex-
actly 180 degrees opposite each other, so the pinion
shaft holes of the two gears and thrust washers are
properly aligned.
(3) Rotate the gears 90 degrees so the pinion shaft
holes of the case are in exact alignment with the
holes in the two thrust washers and pinions.
(4) From the pinion shaft lock pin hole side of the
case, insert the slotted portion of the pinion shaft
through the case, the conical thrust washer, and
through just one pinion gear.
(5) Install the thrust block through the hub
so
that
the slot is centered between the side gears.
(6) While keeping all of these parts in proper align-
ment, push the pinion shaft into the case until the
locking pin hole in the pinion shaft is in exact align-
ment with its respective hole in the case and
install
the pinion shaft lock pin through the hole in the case
from the pinion shaft side of the drive gear flange,
(8.75
inch gear). (On the
8.25
inch gear, install the pin
from the opposite side).
(7)
Make certain the contacting surfaces of the
drive gear and the case flange are clean and free from
any burrs and position the drive gear on the case,
aligning the threaded holes of the drive gear with
those in the case flange.
(8) Insert the drive gear cap screws (left hand
threads) through the case flange and into the drive
gear. After all cap screws are properly started, tap
the drive gear into position on the flange.
(9) Place the unit between the brass jaws of a
vise and alternately tighten each cap screw to 60 foot
pounds torque.
(10) Position each differential bearing cone squarely
on the hubs of the case (taper away from ring gear)
and with installing Tool DD-1005, install the bearing
cones. An arbor press may be used in conjunction with
the installing tool.
Pinion Bearing Cup Installation
(1) Place the bearing cups squarely in position. As-
semble Tool C-758 (Fig. 25) by placing spacer (SP-
2919) (8.75 inch gear with spacer only). (Spacer SP-
3639 for the 8.25 inch gear) followed by the rear
pinion bearing cone over the main screw of the tool
and inserting
it into the carrier from the gear side.
(2)
Place the front pinion bearing over the main
screw followed by compression sleeve SP-535, cen-
tralizing washer SP-534, and main screw nut SP-533.
Hold the compression sleeve with companion flange
holding Tool C-3281 and tighten the nut, (Figure 26)
allowing the tool to rotate as the nut is being tight-
ened in order not to damage the bearings or cups.
NOTE: Do
not remove the tool after installing the
cups.
Two types of drive pinions are used. The method
of determining pinion depth of mesh and bearing pre-
load are the same for both pinions, however the se-
quence of making the two adjustments changes. Pin-
_.
.
.--..
PINION LOCATING
SPACER
SP-2919 SP-1730
SP-539
NK68
Fig. 25-Rear
Axle Setting Gauge Set
C-758-D4
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