Title: Differential Rebuild - Part 4 of 4
Owner: Don B , added Feb 26 2013 16:12:29
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2358x1310 229kb(If the image has failed to load, click on it to view large version) Description: The pinion nut is a “Distorted Thread Lock Nut” or “Jet Nut” type and must not be reused. Note how much more ovate the opening of the new nut (right) is compared to the now-rounded opening on the old nut, which has lost much of its capacity to resist loosening from vibration and rotation.
3200x1954 229kb(If the image has failed to load, click on it to view large version) Description: Preload is measured with an inch-pound torque wrench. Tap the pinion shaft to seat the bearings. Rotate the pinion CW at least 4 times, and while continuing the rotation at a constant speed, observe the measurement on the torque wrench. Tighten the nut until preload is within spec, 35-55 lb-in.
2634x2182 222kb(If the image has failed to load, click on it to view large version) Description: The four essential differential adjustments are pinion bearing preload, pinion depth, backlash, and carrier bearing preload. The latter three are determined by shim rings of varying thicknesses. Through your research and experience rebuilding your diff, you will become a virtual expert on shims…
2154x2778 215kb(If the image has failed to load, click on it to view large version) Description: By measuring the gear mesh I determined that the pinion depth with new bearings was good, so I moved on to setting the backlash and carrier preload. If your old carrier bearings are in good nick, seriously consider leaving them alone so at most you’ll only have to adjust the pinion shim.
2738x2288 211kb(If the image has failed to load, click on it to view large version) Description: By cocking the carrier bearing races very slightly, you can tap the carrier back into the case with a dead blow mallet. If too much force is required, pull the carrier, reset the race cocking and try again. If it won’t tap in with moderate force, reduce the shim thickness on both sides equally.
1359x933 202kb(If the image has failed to load, click on it to view large version) Description: It will take several attempts with different shim combinations before you get it right, so the carrier and bearing caps go in and out, in and out while you hone in on the correct combination of shims, testing the gear mesh and backlash each time until both are within spec.
3374x2162 229kb(If the image has failed to load, click on it to view large version) Description: Carrier preload is set by adding equal shim thickness to both sides so the carrier fits tight enough in the case to prevent backlash from opening up under load, but not so tight as to stretch the case. A Spicer manual states carrier preload should increase the pinion-only preload by 5 to 13 lb-in.
1850x2044 228kb(If the image has failed to load, click on it to view large version) Description: When the gear mesh matches one of the patterns on the “acceptable” chart, and the backlash is within specification, congratulate yourself. As a do-it-yourself mechanic, you have achieved something well worth celebrating!
1950x1838 227kb(If the image has failed to load, click on it to view large version) Description: Before final assembly, I pulled the carrier one more time, masked the openings and pinion shaft, and gave the case two coats of Rustoleum satin black paint. Hi-temp engine or disc brake caliper paint would have been better, but I had used my last can on the brake disc splash shields.
2900x2063 226kb(If the image has failed to load, click on it to view large version) Description: The diff holds about 2-1/2 quarts of oil. For convenience, I poured in the first 2 quarts while the diff cover was still off. I installed the cover, let the silicone set up, then laid the diff so it was level, squirted in more oil till it began to run out of the fill hole, and installed the plug.
2400x2726 227kb(If the image has failed to load, click on it to view large version) Description: I used Permatex Ultra Gray rigid silicone sealant on the cover. The Dana manual shows how to apply the bead inside the cover screw holes as shown.
3811x2229 231kb(If the image has failed to load, click on it to view large version) Description: Ready for reinstallation and many years of reliable motoring. For more information, see my other photo albums on Diff Removal & Installation and Diff Output Shaft Bearing Replacement. Would I rebuild again? Honestly, I might seriously consider a professionally-rebuilt exchange unit instead…
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