Differential Alignment

CAUTION:
When a new front differential is installed, the following alignment procedure MUST be carried out before fully tightening the differential bolts and installation of the front propeller shaft.

NOTE:
This alignment procedure will be incorporated into the RAVE Workshop Manual at the next edition.





1. Remove and discard the 0 ring from the differential drive tube ("A" in Figure 1).

CAUTION:
All grease must be removed.

2. Thoroughly clean the differential drive tube splines ("B" in Figure 1) and the propeller shaft splines.

3. Install the propeller shaft to the differential drive tube.





4. Slide the propeller shaft forwards and fit the centering flange ("A" in Figure 2) to the propeller shaft.

5. Temporarily secure the centering flange with a suitable nut and bolt. ("B" in Figure 2)





6. Rotate the centering flange to allow the alignment tool to be placed in position (Figure 3).

7. Remove one slider from the alignment tool (LRT-54-032) and set aside.

8. Position the alignment tool into the bushing opening in the transfer gearbox front output flange. (Arrowed in Figure 3)

9. Using a 2 mm Allen wrench, loosen the slider screw so that the slider moves freely along 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.





10. Slide the propeller shaft rearwards until the centering flange nipple is nearly in contact with the alignment tool surface. (Figure 4).

11. Position the alignment tool vertically with the slider below the centering flange nipple.

12. Gently pull the propeller shaft down to its lowest position.

13. Tighten the slider screw to identify the extent of movement.

NOTE:
The alignment tool may have to be rotated into a horizontal position to note the measurement.

14. Record the measurement on the alignment tool, at the inside edge of the slider. (Inset Figure 4).

15. Loosen the slider screw so that the slider moves freely along the rule.

16. Position the alignment tool vertically with the slider above the centering flange nipple.

17. Gently push the propeller shaft up to its highest position and move the slider down to the top of the centering flange nipple.

18. Tighten the slider screw using the Allen wrench.

NOTE:
The alignment tool may have to be rotated into a horizontal position to note the measurement.





19. Record the measurement on the alignment tool, at the inside edge of the slider. (Inset Figure 5)

20. If the recorded measured distances above and below the locating bushing are equal within 1 mm, the differential is correctly aligned to the transfer box front output flange. Go to section "Install Front Propeller Shaft".

21. If the measured distances are not equal within 1 mm, go to section "Adjustment of Differential Alignment".