Tracker Off-Road 800SX Service Manual page 147

GC035
2. Zero the dial indicator; then push the ring gear
toward the dial indicator and release. End-play
should be 0.004-0.008 in.
3. To increase end-play, decrease the shim thickness. To
decrease end-play, increase the shim thickness.
NOTE: Once proper backlash and end play are

established, the gear case can be assembled.
Assembling Differential Assembly
1. With the pinion gear and new bearings installed,
place the selected (backlash) shim on the gear case
side of the ring gear with the chamfered side toward
the ring gear; then install into gear case/differential
housing.
GC031A
GC020
2. Place the selected (end-play) shim, chamfered side
toward the gear, onto the cover side of the ring gear.
GC036B
NOTE: The spider and ring gear assembly must be

replaced as a complete unit.
3. Apply a liberal coat of grease to the O-ring; then
install it on the assembled cover assembly making
sure to seat the O-ring completely down around the
circumference of the inner cover.
GC075B
4. Making sure the O-ring is properly positioned on the
differential housing cover assembly, install the cover
with existing cap screws (coated with green Loctite
#270). Tighten the cap screws evenly to 22 ft-lb
(29.9 N-m).
NOTE: Grease can be applied to the O-ring for ease

of assembling.
NOTE: If a new housing is being installed, tighten

the cap screws to 28 ft-lb (38.1 N-m).
5. Install the shift fork shaft w/spring into the housing
making sure the shaft O-ring is positioned to the
inside.
XR354
145