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ZF-26
AXLES
Pinion Variance Chart
Old Pinion
Marking
New Pinion Marking
Old Pinion
Marking
- 4
- 3
- 2
- 1
0
+ 1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
- 0 . 0 0 1
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
+ 1
+0.005
+0.004
+0.003
+0.002
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
0
+0.004
+0.003
+0.002
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
- 0 . 0 0 4
- 1
+0.003
+0.002
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
- 0 . 0 0 4
- 0 . 0 0 5
- 2
+0.002
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
- 0 . 0 0 4
- 0 . 0 0 5
- 0 . 0 0 6
- 3
+0.001
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
- 0 . 0 0 4
- 0 . 0 0 5
- 0 . 0 0 6
- 0 . 0 0 7
- 4
0
- 0 . 0 0 1
- 0 . 0 0 2
- 0 . 0 0 3
- 0 . 0 0 4
- 0 . 0 0 5
- 0 . 0 0 6
- 0 . 0 0 7
- 0 . 0 0 8
CAUTION: Do not attempt
to use the starter
shim
thickness determined by the pinion variance chart as the
final shim setting. An actual pinion depth
measurement
must be performed and final shim thickness adjusted as
necessary.
(4) Install rear bearing on pinion gear using arbor
press. Install bearing so large diameter of bearing cage
faces gear end of pinion and press bearing against pinion
head.
(5) Clean pinion bearing bores in axle housing thor-
oughly. This is important to obtaining correct pinion
gear depth adjustment.
(6) Install starter pinion depth shim in housing rear
bearing cup bore. Be sure shim is centered in bearing
cup bore.
NOTE: If the shim is chamfered, be sure the cham-
fered side faces the bottom of the bearing cup bore.
(7) Install rear bearing cup using Driver Handle J-
8092 and Cup Installer J-8608 (fig. 2F-37).
(8) Install front bearing cup using Driver Handle J-
8092 and Cup Installer J-8611-01.
(9) Install pinion gear. Be sure rear bearing is
seated in rear bearing cup.
(10) Install front bearing, rear universal joint yoke,
and original pinion nut on pinion gear. Tighten pinion
nut only enough to remove bearing end play.
CAUTION: Do not install a new pinion nut and collap-
sible spacer at this time as the pinion gear will be re-
moved after depth
measurement.
(11) Note pinion depth variance marked on pinion
gear. If number is preceded by a plus (+) sign, add that
amount (in thousands) to standard setting for axle
model being overhauled. If number is preceded by a
minus (-) sign, subtract that amount (in thousandths)
from standard setting. Result of this addition or sub-
8 0 7 0 2
Fig. 2F-37
Pinion Rear Bearing Cup Installation
traction is desired pinion depth. Record this figure for
future reference.
(12) Assemble Arbor Tool J-5223-4 and Discs J-5223-
23 and install assembled tools in differential bearing cup
bores (fig. 2F-38). Be sure discs are completely seated in
bearing cup bores.
(13) Install bearing caps over discs and install bear-
ing cap bolts (fig. 2F-38). Tighten bearing cap bolts se-
curely, but not to specified torque.
(14) Install Gauge Block J-5223-20 (fig. 2F-38). Posi-
tion block so that plunger is directly underneath gauge
arbor and flat surface on opposite side of block is seated
on end face of pinion.
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Troubleshooting
