Side Bearing Preload & Final Assembly, 190 Model Axle

1. The required thicknesses of the left and right adjusting washers can be obtained from the following formulas: T1 = A - C + D + E H + .18 mm; T2 = B - D + F + H + .15 mm; where T1 = required thickness of left side washer in millimeters, T2 = required thickness of right side washer in millimeters, A & B = figures marked on gear carrier, C & D = figures marked on differential case, E & F = side bearing measurements as determined in step 2 and H = figure marked on ring gear.

Fig. 11 Side bearing thickness measuring tools:

2. Calculate how far under standard thickness of 20 mm the side bearings are using tools J25407-1, J25407-2 and J25407-3 or equivalents, Fig. 11 as follows:
a. Set weight block, 4 step gauge block and dial indicator on base plate.
b. Adjust dial indicator to zero.
c. Carefully slide 4 step gauge block and weight block out from under dial indicator.
d. Lubricate side bearing and place side bearing on base plate, ensuring that base plate has recess in it and that bearing will turn freely when positioned over recess.
e. Place weight block on side bearing.
f. Slide dial indicator onto weight block.
g. Rotate weight block several times to ensure that bearing is properly seated.
h. Read dial indicator. Indicator should read .10-.30 mm. If needle fluctuates erratically, bearing is either dirty or defective and should be cleaned or replaced as necessary.
i. Measurement obtained for left side bearing is measurement E, step 1 and measurement obtained for right side bearing is measurement F.
3. Press in front and rear bearing outer races.
4. Install selected pinion height adjusting washer in drive pinion and press in rear bearing outer race.
5. Place pinion front bearing inner race in gear carrier.
6. Apply suitable lubricant to cavity at sealing lips of oil seal, then install front oil seal.
7. Install drive pinion washer, collapsible spacer and drive pinion in gear carrier.
8. Install companion flange and hold firmly, then insert pinion into companion flange.
9. Temporarily tighten pinion nut until there is no axial play. Ensure that threaded portion of drive pinion and pinion nut are free from oil or grease.
10. Tighten pinion nut by degrees until preload is 9.5-13.9 inch lbs.
11. Install differential case assembly with side bearing outer races into gear carrier.
12. Align mark on bearing cap with mark on gear carrier and install bearing cap on gear carrier.
13. Measure ring gear to drive pinion backlash with dial indicator. If backlash is less than .0059-0079 inch, decrease thickness of left shim and increase thickness of right shim by same amount. If backlash exceeds .0059-.0079 inch, increase thickness of right shim and decrease thickness of left shim by same amount. Never change the total amount of shims to prevent changing bearing preload.
14. Check total preload, which should be 10-19 inch lbs. If preload is too great, remove same amount of shims from each side. If preload is too small, install same amount of shims on each side.
15. Recheck ring gear to drive pinion backlash and check run out of gear. If backlash varies excessively in different places, foreign matter may be trapped between ring gear and differential case.
16. If backlash varies greatly and ring gear run out is .0031 inch or less, the hypoid gear set or differential case needs to be replaced.