Advertisement
4-18
DIFFERENTIAL CASE ASSEMBLY
AND INSTALLATION
ASSEMBLY
1.
Lubricate all the differential
parts with the recommended rear
axle hypoid lubricant, before they
are installed.
2. Install a side gear with thrust
washer in the larger part of the
differential case.
8. Place thrust washers on both
differential pinions and mesh the
pinions with the differential side
gear in the larger part of the diff-
erential housing, having the pin-
ions 180 deg. apart.
4. Rotate the gears to align the
pinions and washers with the shaft
holes in the case.
5. Install the pinion shaft with
care not
to
damage
the thrust
washers and to have the hole in
the shaft aligned with the lock pin
hole in the case.
6.
Assemblies fitted with four
pinion differentials must have the
differential block fitted to the p:n-
ion shaft between the differential
pinions. The differential half-shafts
and the additional two 'pinions are
then fitted.
7. Install
the
remaining
gear
with thrust washer, in the small
part of the differential case.
FIG. 38
-Drive Pinion
Bearing Removal and
Installation
GROUP
4-REAR AXLE
8. Use the lock pin to locate
the two parts of
the
differential
case, and press them together.
9.
Place the drive gear on the
differential case
and
install
the
bolts. Torque the bolts to 40-50 lb.
/ft.
INSTALLATION
DIFFERENTIAL BEARING
PRELOAD
1. Select any two spacer wash-
ers and place one against each of
the ditferential bearing cups. Place
the cups on the bearing cones and
install the differential assembly in
the carrier. When installed, there
should be a small amount of end
play.
2. With
the
differential
held
firmly against one side of the car-
rier, use a feeler gauge on each
side of the centre line of the case
to measure the end play oetween
the cup and the spacer. (See Fig.
40 ).
Rotate the carrier to seat the
bearing with the feeler gauges in
position, and check to see that the
end play has not been increased by
this procedure. Assuming two .258"
spacers were used, and .012" feeler
gauges were needed
to eliminate
the end play, then two .264" spac-
ers would also produce zero end
play. (i.e . . 258"
+
.012"/2).
3. Tentatively
select
spacers
which will increase the total spacer
thickness. .004" (i.e. increase the
spacer on each side .002", e.g. each
spacer becomes .266").
4.
Fit the carrier spreader ad-
aptors
Fig.
41
and the spreader to
the carrier, together with a dial
indicator
Fig. 42, positioned over
the carrier differential opening, as
close as possible to the centre line
of the axle shafts. This may be
done by using a pilot stud screwed
into the side bearing lower stud
FIG. 39
-Drive Pinion
Preload Check
hole, with the dial indicator plung-
er in contact with the opposite side
of the carrier opening.
5. Use the spreader to expand
the case until the differential as-
sembly with bearings and selected
spacers will fit into the carrier.
A spread of .010" to .012" is us-
ually sufficient UNDER NO CIR-
CUMSTANCES
SHOULD
THE
CARRIER
BE
SPREAD
MORE
THAN .020".
6. The
differential
assembly,
with bearing cups and the selected
spacers held against the bearing
cones, may now be fitted to the
carrier, first removing the dial in-
dicator.
7.
Release
and
remove
the
spreader tool.
8. Fit the bearing caps, tight-
ening the bolts to 35-45 lb. !'t. tor-
que. Note that the caps are identi-
fied by a brand on the side of the
cap and on the carrier. The caps
MUST be replaced in their original
positions, as they are not inter-
changable.
9.
Rotate
the
differential
as-
sembly at least six times to seat
the bearing rollers.
10. Check the preload by meas-
uring with a spring balance the
tension in a string wrapped around
the differential case on the larger
diameter (6.12") just behind the
drive gear
(
Fig.
43 ) .
Minimum
balance reading must be 3.3 lbs.,
maximum 6.5 lbs. (equals 10 to
20 lb. in preload torque).
11.
Remove the assembly from
the carrier, using the spreader. I!
the preload is correct, tie the sel-
ected spacers to the bearing cups
to have them available for use in
determining gear backlash.
If
the
preload is incorrect, select larger
or smaller spacers to increase or
decrease preload, then repeat steps
4
to 11.
DRIVE GEAR AND PINION
BACKLASH
1.
Install the pinion in the car-
rier in accordance with the proce-
dure of paragraphs 1-9 of Drive
Pinion Assembly and
Installation.
2. Install the differential assem-
bly with the tentatively selected
spacers in the carrier, following
Advertisement
