Tracker Off-Road 500S Service Manual page 130

PK208A
5. Place the appropriate Backlash Measuring Tool (24
spline axle) into the splines of the ring gear and
install a dial indicator making sure it contacts the
gauge at a 90° angle and on the index mark.
GC040
PK220A
6. Zero the dial indicator; then while holding the pinion
stationary, rock the ring gear assembly forward and
back and record the backlash. Backlash must be
0.002-0.010 in. If backlash is within specifications,
proceed to Ring Gear End-Play.
NOTE: If backlash is not within specifications,

increase the case side shim thickness and decrease the
cover side shim thickness. To decrease the backlash,
decrease the case side shim thickness and increase the
cover side shim thickness.
 NOTE: Higher backlash settings usually result in
quieter gear operation.
128
PK220B
Ring Gear End-Play
After correcting backlash, ring gear end-play can be
adjusted. To adjust end-play, use the following proce-
dure:
1. Secure the gear case in a holding fixture with the
cover side up; then install a dial indicator contacting
the ring gear axle flange.
PK221
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 cover side shim
thickness. To decrease end-play, increase the cover
side 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.