Differential Case Installation

Differential Case Installation-Condition 2

Follow this procedure when original differential bearing shims are not available or when rear axle housing differential case or differential bearing replacement is required.






1. With pinion depth set and pinion installed place the differential case/gear subassembly with differential bearings and differential bearing cups in rear axle housing.






2. Installs 6.25 mm (0.265-inch) differential bearing shim on the LH side.






3. Install LH bearing cap finger-tight.






4. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be assembled with a slight drag feel.






5. Install RH side bearing cap and differential bearing cap bolts. Tighten to 102-122 Nm (75-90 lb.ft).






6. Rotate the assembly to ensure tree operation.






7. Check gear and pinion backlash. If backlash is within specification go to Step 14. If backlash is not within specification go to Step 10. If zero backlash is measured proceed with Step 8.






8. If a zero backlash condition occurs add 0.50 mm (0.020 inch) to the RH side and subtract 0.50 mm (0.020) inch from the LH side to allow backlash indication.
9. Check backlash as outlined in Step 7.
10. If backlash is not to specification correct backlash by increasing thickness of one differential bearing shim and decreasing thickness on the other differential bearing shim by the same amount. Refer to the following illustrations for approximate differential bearing shim change.






Backlash Adjusting






Backlash/Thickness Chart






Shim Demensions
















Differential Shim Size Chart

Adjusting Backlash






11. Install differential bearing shim and bearing caps. Tighten caps to 102-122 Nm (75-90 lb-ft).






12. Rotate assembly several times.






13. Recheck backlash as outlined in Step 7. If backlash is within specification proceed to Step 14. If not repeat Step 10.






14. Increase both LH and RH shim sizes by 0.1524 mm (0.006 inch) and install for correct differential bearing preload. Make sure the differential bearing shims are fully seated and the assembly turns freely.
15. Use a white marking compound to obtain a tooth mesh contact pattern in the assembly. Pattern legibility can be improved by connecting the driveshaft (4602) and rotating both wheels in the drive and coast direction.






Tooth Contact Guidelines

Pattern inspection allows the technician to detect gross errors inset-up prior to complete assembly. Pattern contact should be within the primary area of the ring gear tooth surface avoiding "narrow" or "hard" contact with the outer perimeter of tooth (top to root toe to heel). Pattern inspection should be on the drive (pull) side. Correct assembly of drive pattern will result in satisfactory coast performance. If gross pattern error is detected with preferred backlash 0.305 to 0.381 mm (0.012 to 0.015 inch) check drive pinion bearing adjustment shim selection.

Axle Shaft Installation Service and Repair