Final Drive

Fig. 3 Exploded View Of Final Drive Unit.:

Refer to Fig. 3 for following disassembly procedures.

Fig. 13 Exploded View Of Differential Case:

Fig. 22 Pressing Side Bearing Inner Race:

Differential Case

1. Measure clearance between side gear thrust washer and differential case.
2. Correct clearance is .0039-.0079 inch.
3. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.
4. Install differential case A and B. Fig. 13.
5. Place differential case on ring gear.
6. Apply suitable locking sealant to ring gear bolts and install. Tighten bolts in cross pattern, lightly tapping bolt head with a hammer.
7. Press fit side bearing inner race on differential case with differential side bearing inner race installation and adaptor tools No. KV38100300 and ST3306100 or equivalents. Fig. 22.

Fig. 23 Differential Carrier Bearing Outer Race Installation:

Differential Carrier

1. Press fit front and rear bearing outer races with drift and adaptor tools No. ST30611000 and ST30613000 or equivalents. Fig. 23.
2. Refer to ADJUSTMENT PROCEDURES and select proper pinion bearing adjusting washer and drive pinion bearing spacer.

Fig. 24 Pinion Rear Bearing Inner Race Installation:

Fig. 25 Drive Pinion Assembly Installation:

Fig. 26 Pressing Drive Pinion Assembly Into Differential Carrier:

3. Install selected drive pinion height adjusting washer in drive pinion. Press fit pinion rear bearing inner race as shown in Fig. 24.
4. Place pinion front bearing inner race in final drive housing.
5. Set drive pinion assembly in differential carrier as shown in Fig. 25.
6. Install drive pinion with press and suitable tool. Fig. 26.
7. Apply suitable multi-purpose grease to cavity at sealing lips of front oil seal and install oil seal.
8. Install companion flange nut. Torque to 137--217 ft. lbs. Ensure threaded portion of drive pinion and pinion nut are free from oil or grease.
9. Turn drive pinion in both directions several times and measure pinion bearing preload.
a. Correct pinion bearing preload is 9.5-12.2 inch lbs.
b. If pinion bearing preload is not within specifications, replace pinion bearing adjusting washer and spacer with a different thickness.
10. Refer to ADJUSTMENT PROCEDURES and select proper side bearing adjusting washer.
11. Install differential case assembly with side bearing outer races into gear carrier.
12. Insert left and right side bearing adjusting washers in place between side bearings and carrier.

Fig. 27 Side Bearing Installation:

Fig. 8 Bearing Cap Matching Mark Location:

13. Drive in side bearing with side bearing spacer drift tool No. KV38100600 or equivalent. Fig. 27.
14. Align mark on bearing cap with mark on gear carrier and install bearing cap on gear carrier. Fig. 8.
15. Check runout of ring gear with suitable dial indicator. Allowable runout is .0020 inches.
16. Measure ring gear to drive pinion backlash with suitable dial indicator.
a. Allowable backlash is .0039-.0059 inches.
b. If backlash is too small, decrease thickness of left shim and increase thickness of right shim by same amount.
c. If backlash is too great, reverse above procedure.
d. Never change total amount of shims as it will change bearing preload.
17. Check total preload with torque wrench as follows:
a. Turn drive pinion in both directions several times to seat bearing rollers correctly.
b. Total preload is 2.6 in. lbs added onto measured value of drive pinion preload.
c. If preload is too great, remove same amount of shim from each side.
d. If preload is too small, add same amount of shim to each side.
e. Never add or remove a different number of shims for each side as it will change ring gear to drive pinion backlash.
18. Recheck ring gear to drive pinion backlash. Increase or decrease in thickness of shims will cause change of ring gear to pinion backlash.
a. If backlash varies excessively in different places, foreign matter may be caught between ring gear and differential case.
b. If backlash varies greatly when ring gear runout is within specified range, replace hypoid gear set or differential case.
c. Allowable ring gear to drive pinion backlash is .0039-.0059 inches.
19. Check tooth contact. Refer to ADJUSTMENT PROCEDURES.
20. Apply multi-purpose grease to cavity at sealing lips of oil seal and install side oil seal.
21. Install rear cover and gasket.