Differential Case Assembly
Pinion, Drive Gear And Differential Case Carrier:
1. Place differential case in vise. Apply grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent, to new side gear thrust washers and to hubs and thrust face of the new side gears. Assemble both side gears. Apply grease to the new spherical washers, and the new pinion mate gears. Assemble new pinion mate gears and washers.
2. Assemble both side gears and thrust washers, hold in place with hand, then assemble the pinion mate gears and washers to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly.
3. Rotate the side gears until the holes of the washers and pinion gears line up with the holes of the case. If the gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn the shaft.
4. Use a drift to line up the holes with those of the differential case.
5. Assemble pinion mate shaft, drive on shaft to remove drift. Be sure lockpin hole of the shaft is lined up with the lockpin hole of the case.
6. Assemble lockpin (roll pin). Peen metal of case over pin to lock in two places 180° apart.
7. Be sure flange face of the case is free of nicks or burrs. Assemble ring gear to case. Line up holes of the ring gear with those of the case. Use new ring gear bolts. Draw up bolts alternately and evenly. Tighten ring gear bolts to 136-163 Nm (100-120 ft-lb).
8. Place the inner axle seals in the axle tube housing. Press both seals in at the same time with an appropriate installation tool. Make sure the seals are pressed in straight and not cocked in the bore. Coat the lips of the seals with Long Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent.
9. Install Master Differential Bearings, Tool DB1T-4222-D or equivalent onto case. Remove all nicks, burrs, dirt, etc., from hubs to allow bearings to rotate freely.
10. Assemble differential case into carrier (less pinion). Mount Dial Indicator D78P-4201-B or equivalent with a magnetic base as shown. Locate tip of indicator on flat surface of one of the ring gear bolt spot faces. Force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero.
NOTE: Dial indicator should have a minimum travel capability of 5.08mm (0.200 inch).
11. Force the differential assembly as far as it will go in the opposite direction. Repeat these steps until you have obtained the same reading. Record the reading of the indicator. This will be the total amount of shims required (less preload) and will be calculated later during assembly. After making sure the readings are correct, remove indicator and differential assembly from housing. DO NOT REMOVE MASTER BEARINGS FROM DIFFERENTIAL CASE AT THIS TIME.
This reading is the total differential case end play which will be needed in Step 6 of Assembly of Differential into Housing.
12. Ring gears and pinions are supplied in matched sets only. Matching numbers on both the pinion and ring gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion and ring gear before proceeding with assembly.
The distance from the centerline of the ring gear to the backface of the pinion (Model 60) is 127mm (5.000 inch).
On the backface of each pinion, there is etched a plus + number, a minus - number, or a zero 0 number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the inner pinion bearing cup.
NOTE: Do not use the backface of the pinion for pinion positioning. The backface of the pinion is no longer a ground surface.
For example-If a pinion is etched a + m+8 (+3) this pinion would require 0.O8mm (0.003 inch) less shims than a pinion etched 0. This means by removing shims, the mounting distance of the pinion is increased, which is just what m+8 (+3) indicates. Or if a pinion is etched m-8 (-3), we would want to add 0.08mm (0.003 inch) more shims than would be required if the pinion were etched 0. By adding 0.O8mm (0.003 inch) shims, the mounting distance of the pinion was decreased, which is just what m-8 (-3) indicated.
If the old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to this same dimension. If a baffle is used in the axle assembly, it is considered as part of the shim pack.
To change the pinion adjustment, shims are available in thicknesses of 0.08, 0.13, and 0.25mm, (0.003, 0.005, and 0.010 inch).
NOTE: If baffle or slinger is bent or mutilated, it should be replaced.
Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original buildup.
If a new gear set is being used, notice the + or - etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures.
For example-If the old pinion reads m+5 (+2) and the new pinion is m-5 (-2), add 0.10mm (0.004 inch) shims to the original shim pack.
PINION SETTING CHART - METRIC
PINION SETTING CHART - ENGLISH