Adjustment of Differential Alignment

CAUTION:
Unequal alignment measurements as depicted in Figures 6 and 7 require differential alignment to the transfer box output flange.

NOTE:
Rotating the differential counter-clockwise will raise the drive tube. This will decrease the excess distance below the locating bush shown in the example (Figure 7). This procedure may need to be repeated several times to achieve the desired result.

1. Slide the propeller shaft forwards, release the centering flange securing nut and bolt, rotate the centering flange and remove the alignment tool. (Figure 3)

NOTE:
The calculated average measurement is the "target" position (maximum up and down) for the propeller shaft in relation to the locating bushing in the transfer gearbox front output flange.

2. Calculate the average of the up and down recorded measurements to obtain the "target" measurement.

3. Release the slider screw on the alignment tool and move the inside edge of the slider to the calculated "target" position.

4. Fully tighten the slider screw with the Allen wrench.





5. Position the alignment tool into the transfer gearbox front output flange locating bushing. (Figure 8).

6. Rotate the centering flange into position and secure with a suitable nut and bolt.

7. Slide the propeller shaft rearwards until it contacts the face of the rule.

NOTE:
It may be necessary to slide the propeller shaft, together with the alignment tool, slightly forwards. This will allow the alignment tool to be slightly extracted from the locating bush in the transfer gearbox front output flange, to allow clearance.

8. If the measured distance was larger below than above the centre line of the locating bushing, position the alignment tool vertically with the slider above the centering flange nipple.

9. If the measured distance was larger above than below the center line of the locating bushing, position the alignment tool vertically with the slider below the centering flange nipple.

NOTE:
The initial movement of the propeller shaft will be due to the fit of the propeller shaft and the drive tube mating splines. When approaching the slider, resistance will be felt as the differential moves.

10. Perform differential alignment as follows:





^ Release the four differential attachment bolts sufficiently to secure the differential, but still allow slight rotation on its axis. (Figure 9)

^ Gently push the propeller shaft up or pull the propeller shaft down until the centering flange nipple touches the inside edge of the slider.

^ With assistance, hold the propeller shaft in this position and snugly tighten one of the differential bolts to secure the differential.

^ Verify the measurement above and below the centering flange nipple is equal and the same as the "target" measurement.

11. Repeat adjustments in step 10 up and down as required to achieve equal alignment measurements.

CAUTION:
A Torque wrench MUST be used when tightening the differential attachment bolts to 110 Nm (81 lbf.ft).

12. When the measurement is equal above and below the locating bush within 1 mm of the "target" position, tighten all bolts securing the front differential to 110 Nm (81 lbf.ft).

13. Verify that the measurement above and below the centering flange nipple remain equal after the torque procedure.