Usage:
Torque for eight nuts (not shown) that fasten housing (17) together to ... 390 ± 14 N·m (290 ± 10 lb ft)
(8) Dowel to protrude 7.9 ± 0.5 mm (.31 ± .02 in) from caps (9) and (22).
Put 2P-2506 Thread Lubricant on the threads of bolts (7) and faces of the washers. Tighten bolts (7) that hold bevel gear (16) to differential housing (17) to a torque of ... 440 ± 14 N·m (320 ± 10 lb ft)
(13) 9M-5874 Shim Pack thickness (new) ... 3.30 mm (.130 in)
(19) Torque for four bolts that hold bearing caps (9) and (22) to differential carrier (5) ... 1100 ± 150 N·m (820 ± 110 lb ft)
(21) Torque for bolts that hold cage (20) to carrier (5) ... 135 ± 20 N·m (100 ± 15 lb ft)
(23) 9D-0021 Shim thickness ... 0.18 mm (.007 in)
9D-0019 Shim thickness ... 0.13 mm (.005 in)
Adjustment Procedure For the Bevel Pinion Bearings:
1. Install bearings (1) and (4) on pinion (3) and then install pinion in the carrier.
2. Install cage (20) and shims (23).
NOTE: Do not install yoke (18), seal (14) and O-rings (2) and (15) in cage (20) until after the adjustment is made. Turn pinion slowly while the adjustment is made.
3. Use shims (23) as necessary behind cage (20) to put enough preload on the pinion bearings so the torque needed to turn pinion (3) is more than 4.0 N·m (35 lb in)
4. Turn the pinion several revolutions. Change thickness of shims (23) so that a torque of 4.0 ± 0.6 N·m (35 ± 5 lb in) is needed to rotate pinion.
5. Put lubricant on seal (14) and O-rings (2) and (15). Install seal (14) and O-ring (2) on cage (20). The lip of seal (14) must be toward bearing (1). Tighten bolts (21) to a torque of 135 ± 20 N·m (100 ± 15 lb ft). Install O-ring (15) and yoke (18) on pinion (3).
Adjustment Procedure For Free Movement (Backlash) Between The Bevel Pinion And The Bevel Gear:
1. Install the gears in differential housing (17). Turn the gears. The torque needed to turn the gears must not be more than ... 35 N·m (25 lb ft)
2. Install differential housing assembly (17) complete with the bearing cups and cones in carrier (5).
3. Install bearing caps (9) and (22) and bolts (19). At this time, do not tighten the bolts to full torque.
4. Put the carrier in a position so the centerline for the axles is vertical and the teeth of bevel gear (16) are toward the top.
5. Use a dial indicator to measure the backlash between bevel gear (16) and pinion (3) at four different points on the bevel gear. Find the average backlash.
6. Turn adjustment ring (6) until the average backlash between bevel gear (16) and pinion (3) is ... 0.36 ± 0.13 mm (.014 ± .005 in)
7. Tighten the four bolts on bearing caps (9) and (22) to a torque of ... 1100 ± 150 N·m (820 ± 110 lb ft)
Adjustment Procedure For Preload Of The Differential Bearing:
1. To get maximum preload on carrier bearings, use a dial indicator to measure change in dimension (B). Fasten the indicator on the differential assembly and put the pointer on bearing cap (22).
2. Turn adjustment ring (6) and increase dimension (B) to ... 0.51 to 0.64 mm (.020 to .025 in)
3. Turn bevel gear in both directions for several revolutions.
4. Decrease dimension (B) to ... 0 mm (0 in)
5. Increase dimension (B) to ... 0.38 ± 0.05 mm (.015 ± .002 in)
6. Use a dial indicator to check the free movement (backlash) between bevel gear (16) and pinion (3). Turn adjustment rings (6) and (24) the same amount and in the same direction until the backlash is ... 0.36 ± 0.13 mm (.014 ± .005 in)
NOTE: If the adjustment rings are turned like this, there will be no change in the preload of the bearings.
Adjustment Procedure To Get Preload (A), Between Bearing Cap (9) And Pin (10):
NOTE: To get the correct preload (A) between pin (10) and bearing cap (9) of the carrier assembly, use the procedure that follows:
1. Install the differential carrier (5) into the axle housing.
2. Install pin (10) and cover (12). Do not install shims (13) at this time.
3. Tighten bolts (11) evenly until pin (10) is against bearing cap (9) of the carrier assembly. Use a feeler gauge to measure the distance between the cover and the axle housing.
4. Make a thickness of shims the same as the distance measured minus 0.05 ± 0.03 mm (.002 ± .001 in). Install shims (13) between cover (12) and the axle housing.