Login- Download PDF Manual
-
DIFFERENTIAL (Continued)
DR
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear
side adjuster
firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup. (13) Tighten pinion gear side adjuster an addi- tional:† New Bearings: 6 Adjuster Holes † Original Bearings: 4 Adjuster Holes (14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 85 N·m (63 ft.
(16) Tighten adjuster lock bolts to 25 N·m (18 ft.
lbs.).
lbs.) (Fig. 39).
(17) Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for pro- cedure.
(18) Install axle shafts and hub bearings. (19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N·m (30 ft. lbs.).
(20) Fill differential with lubricant, refer to Lubri- cation & Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N·m (24 ft.
lbs.).
DIFFERENTIAL CASE BEARINGS REMOVAL
(1) Remove the differential case from the housing. (2) Install Plug 8888 into the end of the case. (3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 40).
Fig.39ADJUSTERLOCKBOLT
1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT 4 - BEARING CAP BOLT
Fig.40DIFFERENTIALCASEBEARING
1 - BRIDGE 2 - SPLITTER 3 - BEARING 4 - PLUG
DR DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION
(1) Set differential case on Plug 8888. (2) Install differenial case bearings with Installer
8881 and Handle C-4171 (Fig. 41).
FRONT AXLE - 9 1/4 AA
3 - 65
Fig.42RINGGEAR
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER
Fig.43FLANGEWRENCH
1 - PINION FLANGE 2 - WRENCH
(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 44).
(10) Remove pinion gear from housing with Pinion
Driver 8976 and a hammer (Fig. 45).
NOTE: Thread drive on shaft until it bottoms out.
(11) Remove pinion seal with a slide hammer or
pry bar.
(12) Remove and discard front pinion bearing
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove collapsible spacer from the pinion
shaft.
Fig.41DIFFERENTIALCASEBEARINGS
1 - HANDLE 2 - DIFFERENTIAL CASE 3 - BEARING 4 - INSTALLER
(3) Install differentail case into housing.
PINION GEAR/RING GEAR REMOVAL
NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove axle shafts. (4) Remove differential from housing. (5) Place differential case in a vise with soft metal
(6) Remove bolts holding ring gear to differential
jaw protectors
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 42).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 43) and remove pinion flange nut and washer.FRONT AXLE - 9 1/4 AA
3 - 66
PINION GEAR/RING GEAR (Continued)DR
Fig.44PINIONFLANGEPULLER
1 - PINION FLANGE 2 - PULLER
Fig.45PINIONDRIVER
1 - PINION SHAFT 2 - PINION DRIVER
Fig.46REARPINIONBEARING
1 - PULLER 2 - VISE 3 - PINION SHAFT 4 - ADAPTER BLOCKS
INSTALLATION
(1) Install front pinion bearing cup (Fig. 47) with
Installer D-146 and Handle C-4171.
(14) Remove rear pinion bearing with Puller
C-293-PA and Adapters 8879 (Fig. 46).
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the
housing with a punch and hammer and discard.
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the if bearing is
housing with a punch and hammer, replaced.
Fig.47FRONTPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
DR PINION GEAR/RING GEAR (Continued)
(2) Install rear pinion bearing cup (Fig. 48) with if bearing is
Installer 8886 and Handle C-4171, replaced.
FRONT AXLE - 9 1/4 AA
3 - 67
(4) Install rear pinion bearing (Fig. 50) with
Installer C-3095-A and a press.
Fig.48REARPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
(3) Install pinion depth shim (Fig. 49) on the pin-
ion gear shaft.
(5) Install new collapsible spacer (Fig. 51).
Fig.50REARPINIONBEARING
Fig.49PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
Fig.51COLAPSIBLESPACER
1 - COLAPSIBLE SPACER 2 - PINION GEAR 3 - REAR PINION BEARING
(6) Lubricate pinion and bearings.
FRONT AXLE - 9 1/4 AA
3 - 68
PINION GEAR/RING GEAR (Continued)(7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8982 (Fig. 52).
DR
† New Pinion Bearings: 1.7-2.8 N·m (15-25 in. lbs.)† Original Pinion Bearings: 1.1-2.2 N·m (10-20
in. lbs.)Fig.52PINIONGEARINSTALLER
1 - INSTALLER 2 - DIFFERENTIAL HOUSING
(8) Install new pinion seal (Fig. 53) with Installer
8882 and Handle C-4171.
Fig.54PINIONROTATINGTORQUE
1 - PINION FLANGE 2 - TORQUE WRENCH
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start two new ring gear bolts.
(17) Install the rest of the new ring gear bolts and
tighten them alternately to seat the ring gear.
(18) Torque ring gear bolts to 140 N·m (103 ft.
lbs.).
(19) Install differential in housing. (20) Measure final rotating torque with an inch pound torque wrench. The final pinion rotating torque plus differential case bearing preload is: † New Bearings: 3.4-5.6 N·m (30-50 in. lbs.) † Original Bearings: 2.8-5.1 N·m (25-45 in. lbs.) (21) Install axle shafts. (22) Verify ring gear backlash and gear contact
(23) Install the propeller shaft with the reference
pattern.
marks aligned.
(24) Install differential cover with gasket and
tighten to 40 N·m (30 ft. lbs.).
(25) Fill differential with fluid and tighten fill plug
to 32 N·m (24 ft. lbs.).
Fig.53PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange onto the pinion shaft, until a few threads are show- ing.
(11) Install pinion flange washer and new pinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
and tighten pinion nut until end play is taken up. (13) Rotate pinion several times to seat bearings. (14) Measure pinion rotating torque with an inch pound torque wrench (Fig. 54). Tighten pinion nut in small increments until pinion rotating torque is:
DR
REAR AXLE - 9 1/4
3 - 69
REAR AXLE - 9 1/4
TABLE OF CONTENTS
page
page
REAR AXLE - 9 1/4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 69
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 74
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 79
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 80AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
DIFFERENTIAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 88
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88DIFFERENTIAL-TRAC-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 89
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 90
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96REAR AXLE - 9 1/4
DESCRIPTIONThe axle consist of a cast iron center section with axle tubes extending from either side. The tubes are pressed into and welded to the differential housing to form a one-piece axle housing (Fig. 1). The axles are equipped with semi-floating axle shafts, meaning vehicle loads are supported by the axle shaft and bearings. The axle shafts are retained by C-locks in the differential side gears.
OPERATION
The axle receives power from the propeller shaft. The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case. The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are splined to the axle shafts.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri- cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are accelera- tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then acceler- ate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly:
† Check for insufficient lubricant. † Incorrect ring gear backlash. † Gear damage. Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during vehi- cle turns. A worn pinion shaft can also cause a snap- ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound. Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing
REAR AXLE - 9 1/4
3 - 70
REAR AXLE - 9 1/4 (Continued)DR
Fig.191/4AXLE
DR REAR AXLE - 9 1/4 (Continued)
REAR AXLE - 9 1/4
3 - 71
1 - HUB 2 - AXLE SHAFT 3 - VENT FITTING 4 - DIFFERENTIAL HOUSING 5 - CUP 6 - FRONT PINION BEARING CONE 7 - NUT 8 - WASHER 9 - COMPANION FLANGE 10 - SEAL 11 - AXLE SHAFT 12 - HUB 13 - STUD 14 - BEARING CUP 15 - REAR PINION BEARING CONE 16 - DIFFERENTIAL BEARING 17 - ADJUSTER 18 - LOCK 19 - BOLT 20 - BEARING CAP 21 - CAP BOLT 22 - BEARING CUP 23 - THRUST WASHER 24 - SIDE GEAR 25 - C-LOCK 26 - DIFFERENTIAL POSITIONS 27 - THRUST WASHER 28 - COVER
noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differen- tial. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front pinion bearing is the source.
Worn or damaged differential bearings usually pro- duce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differen- tial bearing noise is also constant and varies only with vehicle speed.
Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn U-joint or by worn side–gear thrust washers. A worn pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually caused by a: † Damaged drive shaft. † Missing drive shaft balance weight(s). † Worn or out-of-balance wheels. † Loose wheel lug nuts. † Worn U-joint(s).
29 - PLUG 30 - COVER BOLT 31 - WASHER 32 - CLIP 33 - SIDE GEAR 34 - THRUST WASHER 35 - DIFFERENTIAL BEARING CONE 36 - C-LOCK 37 - BOLT 38 - LOCK 39 - BEARING CUP 40 - ADJUSTER 41 - BEARING CUP 42 - BOLT 43 - PINION MATE SHAFT 44 - EXCITER RING 45 - DIFFERENTIAL CASE 46 - RING GEAR BOLT 47 - RING GEAR 48 - PINION 49 - PINION GEAR DEPTH SHIM 50 - PRELOAD COLLAPSIBLE SPACER 51 - SEAL 52 - AXLE SHAFT BEARING 53 - AXLE SHAFT TUBE 54 - AXLE TUBE 55 - AXLE SHAFT BEARING 56 - SEAL
† Loose/broken springs. † Damaged axle shaft bearing(s). † Loose pinion gear nut. † Excessive pinion yoke run out. † Bent axle shaft(s). Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rearend vibra- tion. Do not overlook engine accessories, brackets and drive belts.
NOTE: All driveline components should be exam- ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: † High engine idle speed. † Transmission shift operation. † Loose engine/transmission/transfer case mounts. † Worn U-joints. † Loose spring mounts. † Loose pinion gear nut and yoke. † Excessive ring gear backlash. † Excessive side gear to case clearance. The source of a snap or a clunk noise can be deter- mined with the assistance of a helper. Raise the vehi- cle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.
REAR AXLE - 9 1/4
3 - 72
REAR AXLE - 9 1/4 (Continued)DIAGNOSTIC CHART
DR
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
1. Inspect axle tube alignment. Correct as necessary.
2. Bent or sprung axle shaft.
2. Inspect and correct as necessary.
Axle Shaft Broke
1. Misaligned axle tube.
2 Vehicle overloaded.
3. Erratic clutch operation.
4. Grabbing clutch.
Differential Cracked
1. Improper adjustment of the differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
Differential Gears Scored
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one wheel/tire.
1. Replace the broken shaft after correcting tube mis-alignment.
2. Replace broken shaft and avoid excessive weight on vehicle. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Replace broken shaft and inspect and repair clutch as necessary.
1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.
2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly. 3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight. 4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.
1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Replace scored gears. Fill differential with the correct fluid type and quantity. 3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.
DR REAR AXLE - 9 1/4 (Continued)
REAR AXLE - 9 1/4
3 - 73
Condition
Possible Causes
Correction
Loss Of Lubricant
1. Lubricant level too high.
2. Worn axle shaft seals. 3. Cracked differential housing. 4. Worn pinion seal. 5. Worn/scored yoke. 6. Axle cover not properly sealed.
1. Drain lubricant to the correct level.
2. Replace seals. 3. Repair as necessary. 4. Replace seal. 5. Replace yoke and seal. 6. Remove, clean, and re-seal cover.
Axle Overheating
1. Lubricant level low.
1. Fill differential to correct level.
2. Improper grade of lubricant.
3. Bearing pre-loads too high. 4. Insufficient ring gear backlash.
Gear Teeth Broke
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
Axle Noise
1. Insufficient lubricant.
2. Improper ring gear and pinion adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or pinion. 5. Loose pinion bearings. 6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap bolts.
9. Housing not machined properly.
2. Fill differential with the correct fluid type and quantity. 3. Re-adjust bearing pre-loads. 4. Re-adjust ring gear backlash.
1. Replace gears. Examine other gears and bearings for possible damage.
2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation. 3. Replace gears and examine remaining parts for damage. 4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.
1. Fill differential with the correct fluid type and quantity. 2. Check ring gear and pinion contact pattern. Adjust backlash or pinion depth. 3. Replace gears with a matched ring gear and pinion. 4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load. 6. Adjust differential bearing pre-load. 7. Measure ring gear run-out. Replace components as necessary. 8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification. 9. Replace housing.
REAR AXLE - 9 1/4
3 - 74
REAR AXLE - 9 1/4 (Continued) REMOVALDR
(1) Raise and support the vehicle. (2) Position a lifting device under the axle. (3) Secure axle to device. (4) Remove wheels and tires assemblies. (5) Remove RWAL sensor from the differential
(6) Remove brake hose at the axle junction block. (7) Disconnect parking brake cables and cable
housing.
brackets.
(8) Remove brake calipers and rotors. (9) Remove axle vent hose. (10) Mark propeller shaft and companion flange
for installation alignment reference.
(11) Remove propeller shaft. (12) Remove shock absorbers from axle. (13) Remove U-bolets from axle. (14) Separate the axle from the vehicle.
INSTALLATION
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install axle U-bolts and tighten to 149 N·m
(110 ft. lbs.).
specification.
housing.
brackets.
(3) Install shock absorbers to axle and tighten to
(4) Install the RWAL sensor to the differential
(5) Connect the parking brake cables and cable
(6) Install brake rotors and calipers. (7) Connect brake hose to the axle junction block. (8) Install axle vent hose. (9) Align propeller shaft and pinion companion flange reference marks and tighten companion flange bolts to 115 N·m (85 ft. lbs.).
(10) Install the wheels and tires. (11) Fill differential to specifications. (12) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets only. The identifying numbers for the ring gear and pinion are painted onto the pinion gear shaft (Fig. 2) and the side of the ring gear. A plus (+) number, minus (–) number or zero (0) along with the gear set sequence number (01 to 99) is on each gear. This first number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion marked with a (0). The next two numbers are the sequence number of the gear set. The standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern for additional infor- mation.
Fig.2PINIONIDNUMBER
1 - VARIANCE NUMBER 2 - SEQUENCE NUMBER
Compensation for
is achieved with select shims. The shims are placed behind the rear pinion bearing. (Fig. 3).
pinion depth variance
Fig.3ADJUSTMENTSHIMLOCATIONS
1 - DIFFERENTIAL HOUSING 2 - COLLAPSIBLE SPACER 3 - PINION BEARING 4 - PINION DEPTH SHIM 5 - PINION GEAR 6 - BEARING CUP
If a new gear set is being installed, note the depth variance painted onto both the original and replace- ment pinion. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns Intersecting figure represents plus or
intersect. minus the amount needed.
Note the painted number on the shaft of the drive pinion (–1, –2, 0, +1, +2, etc.). The numbers repre-
DR REAR AXLE - 9 1/4 (Continued)
REAR AXLE - 9 1/4
3 - 75
sent thousands of an inch deviation from the stan- dard. If the number is negative, add that value to the required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of the depth shim. If the number is 0 no change is nec- essary.
Original Pinion
Gear Depth
Variance
+4
+3
+2
+1
21
22
23
2424
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001PINION GEAR DEPTH VARIANCE
Replacement Pinion Gear Depth Variance
23
22
21
+1
+2
+3
+0.001
+4
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001+0.003
+0.002
+0.001+0.002
+0.001+0.005
+0.004
+0.003
+0.002
+0.001+0.004
+0.003
+0.002
+0.00120.001
20.001 20.002
20.001 20.002 20.003
20.001 20.002 20.003 20.004
20.001 20.002 20.003 20.004 20.005
20.001 20.002 20.003 20.004 20.005 20.006
20.001 20.002 20.003 20.004 20.005 20.006 20.007
20.001 20.002 20.003 20.004 20.005 20.006 20.007 20.008PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indi- cator C-3339 (Fig. 4).
(1) Assemble Pinion Height Block 6739, Pinion Block 8542 and rear pinion bearing onto Screw 6741
(Fig. 4).(2) Insert assembled height gauge components, rear bearing, and screw into the housing through pinion bearing cups (Fig. 5).
(3) Install front pinion bearing and Cone-Nut 6740
hand tight (Fig. 4).
(4) Place Arbor Disc 8541 on Arbor D-115-3 in posi- tion in the housing side bearing cradles (Fig. 6). Install differential bearing caps on arbor discs and tighten cap bolts to 41 N·m (30 ft. lbs.).
NOTE: Arbor Discs 8541 has different step diame- ters to fit other axles. Choose proper step for axle being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion height block (Fig. 4). Hold scooter block in place and zero the dial indicator. Tighten dial indicator face lock screw.
Fig.4PINIONDEPTHGAUGETOOLS
1 - DIAL INDICATOR 2 - ARBOR 3 - PINION HEIGHT BLOCK 4 - CONE 5 - SCREW 6 - PINION BLOCK 7 - SCOOTER BLOCK 8 - ARBOR DISC
REAR AXLE - 9 1/4
3 - 76
REAR AXLE - 9 1/4 (Continued)DR
Fig.5PINIONHEIGHTBLOCK
Fig.7PINIONGEARDEPTHMEASUREMENT
1 - PINION BLOCK 2 - PINION HEIGHT BLOCK
1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR
0.076 mm (0.003 in.).
preload and ring gear backlash.
during all backlash measurements.
† The maximum ring gear backlash variation is † Mark the gears so the same teeth are meshed † Maintain the torque while adjusting the bearing † Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise. † Insufficient adjuster torque will not support the ring gear correctly and can cause excessive differen- tial case free-play and ring gear noise.
Fig.6PINIONDEPTHTOOLS
1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK
(7) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block against the pinion height block (Fig. 7). Continue moving the dial probe to the crest of the arbor bar and record the highest reading.
(8) Select a shim equal to the dial indicator read- ing plus the drive pinion gear depth variance number marked on the shaft of the pinion. For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
The following must be considered when adjusting
bearing preload and gear backlash:
NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments: † Maintain the gear teeth engaged (meshed) as marked. † The bearings must be seated by rapidly rotat- ing the pinion gear a half turn back and forth. † Do this five to ten times each time the threaded adjusters are adjusted.
(1) Throught the axle tube use Wrench C-4164 to adjust each threaded adjuster inward until the differ- ential bearing free-play is eliminated. Allow some ring gear backlash approximately 0.25 mm (0.01 in.) between the ring and pinion gear. Seat the bearing cups with the procedure described above.
(2) Install dial indicator and position the plunger against the drive side of a ring gear tooth (Fig. 8). Measure the backlash at 4 positions, 90 degrees apart around the ring gear. Locate and mark the area of minimum backlash.
DR REAR AXLE - 9 1/4 (Continued)
(3) Rotate the ring gear to the position of the least backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed.
Fig.8RINGGEARBACKLASH
1 - DIAL INDICATOR 2 - RING GEAR 3 - EXCITER RING
(4) Loosen the right-side,
tighten the left-side threaded adjuster. Obtain backlash of 0.076 to 0.102
mm (0.003-0.004 in.) with each adjuster tightened to 14 N·m (10 ft. lbs.). Seat the bearing cups with the procedure described above.(5) Tighten the differential bearing cap bolts 136
N·m (100 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N·m (75 ft. lbs.). Seat the bearing cups with the pro- cedure described above. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.)(7) Measure the ring gear backlash. The range of
backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).
(8) Continue increasing the torque at the right- side threaded adjuster until the specified backlash is obtained.
NOTE: The left-side threaded adjuster torque should have approximately 102 N·m (75 ft. lbs.). If the torque is considerably less, the complete adjustment procedure must be repeated.
(9) Tighten the left-side threaded adjuster until 102 N·m (75 ft. lbs.) torque is indicated. Seat the bearing rollers with the procedure described above. Do this until the torque remains constant.
(10) Install
the
threaded adjuster
locks and
tighten the lock screws to 10 N·m (90 in. lbs.).
REAR AXLE - 9 1/4
3 - 77
GEAR CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor- rect running position of the ring and pinion gears. This will produce low noise and long gear life. Gears which are not positioned properly may be noisy and have shorten gear life.
(1) Wipe clean each tooth of the ring gear. (2) Apply gear marking compound to all of the ring
gear teeth.
tion.
(3) Verify bearing cap bolts are torque specifica-
(4) Apply parking brakes lightly to create at 14
N·m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern: † Gear contact pattern is correct (Fig. 9). Backlash
and pinion depth is correct.
Fig.9CORRECTCONTACTPATTERN
† Ring gear too far away from pinion gear (Fig. 10). Decrease backlash, by moving the ring closer to the pinion gear using the adjusters.
Fig.10INCORRECTBACKLASH
1 - COAST SIDE TOE 2 - DRIVE SIDE HEEL
REAR AXLE - 9 1/4
3 - 78
REAR AXLE - 9 1/4 (Continued) † Ring gear too close to pinion gear (Fig. 11). Increase backlash, by moving the ring away from the pinion gear using the adjusters.DR
Fig.13INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE TOE
Fig.11INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL
† Ring gear too far away from pinion gear (Fig. 12). Decrease backlash, by moving the ring closer to the pinion gear using the adjusters.
Fig.14LOWPINIONHEIGHT
Fig.15HIGHPINIONHEIGHT
(2) Measure each side gear clearance. Insert a matched pair of feeler gauge blades between the gear and differential housing on opposite sides of the hub (Fig. 16).
(3) If side gear clearances is no more than 0.005
inch. Determine if the axle shaft is contacting the pinion mate shaft. Do not remove the feeler gauges, inspect the axle shaft with the feeler gauge inserted behind the side gear. If the end ofFig.12INCORRECTBACKLASH
1 - DRIVE SIDE HEEL 2 - COAST SIDE HEEL
† Ring gear too close to pinion gear (Fig. 13). Increase backlash, by moving the ring away from the pinion gear using the adjusters. † Pinion gear set too low (Fig. 14). Increase pinion gear height, by increasing the pinion depth shim thickness. † Pinion gear set too high (Fig. 15). Decrease pin- ion depth, by decreasing the pinion depth shim thick- ness.
SIDE GEAR CLEARANCE
When measuring side gear clearance, check each gear independently. If it necessary to replace a side gear, replace both gears as a matched set.
(1) Install the axle shafts and C-locks and pinion
mate shaft.
DR REAR AXLE - 9 1/4 (Continued)
REAR AXLE - 9 1/4
3 - 79
Fig.17SIDEGEARCALCULATIONS
Fig.16SIDEGEARCLEARANCE
1 - FEELER GAUGE 2 - SIDE GEAR
the axle shaft is not contacting the pinion mate shaft, the side gear clearance is acceptable.
(4) If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear clear- ance. Remove the thrust washer and measure its thickness with a micrometer. Add the washer thick- ness to the recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness of replacement thrust washer (Fig. 17).
In some cases, the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted. The C-lock is preventing the side gear from sliding on the axle shaft.
(5) If there is no side gear clearance, remove the C-lock from the axle shaft. Use a micrometer to mea- sure the thrust washer thickness. Record the thick- ness and re-install the thrust washer. Assemble the differential case without the C-lock installed and re- measure the side gear clearance.
(6) Compare both clearance measurements. If the difference is less than 0.012 inch (0.305 mm), add clearance recorded when the C-lock was installed to thrust washer thickness measured. The sum will determine the required thickness of the replacement thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or greater, both side gears must be replaced (matched set) and the clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION
Axle Ratio
Differential Case Flange Runout
Differential Case Clearance
Ring Gear Diameter Ring Gear Backlash Ring Gear Runout
Pinion Bearing Preload - New Bearings
Pinion Bearing Preload - Original Bearings
SPECIFICATION 3.21, 3.55, 3.92
0.076 mm (0.003 in.) 0.12 mm (0.005 in.) 235 mm (9.25 in.)
0.12-0.20 mm (0.005-0.008 in.)
0.12 mm (0.005 in.)
1.7-4 N·m (15-35 in. lbs.) 1-2 N·m (10-20 in. lbs.)
REAR AXLE - 9 1/4
3 - 80
REAR AXLE - 9 1/4 (Continued)TORQUE SPECIFICATIONS
DR
DESCRIPTION
Differential Cover Bolts
Bearing Cap Bolts Ring Gear Bolts
Pinion Nut Minimum Adjuster Lock Screw Backing Plate Bolts
Pinion Mate Shaft Lock
Screw
Axle U-Bolt Nuts
SPECIAL TOOLS
N·m 41
136
157
285
10
6511
149
Ft. Lbs.
In. Lbs.
30
100
115
210
7.5
48110
90
PULLER6790
REMOVER6310
INSTALLERC-4198
HANDLEC-4171
INSTALLERC-4076-B
HANDLEC-4735-1
DR REAR AXLE - 9 1/4 (Continued)
REAR AXLE - 9 1/4
3 - 81
HOLDER6719
ADAPTERSC-293-37
PULLERC-452
PLUGSP-3289
INSTALLERC-3718
ADAPTERSC-293-47
WRENCHC-4164
PULLERC-293-PA
INSTALLERC-4340
FIXTURE8138
REAR AXLE - 9 1/4
3 - 82
REAR AXLE - 9 1/4 (Continued)DR
INSTALLERC-4345
TRAC-LOKTOOLS8140
REMOVERC-4307
TRAC-LOKTOOLS6960
INSTALLERC-4308
PINIONBLOCK8540
INSTALLERD-130
ARBORDISCS8541
INSTALLERC-3095-A
PINIONGAUGESET6775
REAR AXLE - 9 1/4
3 - 83
DR
AXLE SHAFTS REMOVAL
(1) Place transmission in neutral. (2) Raise and support the vehicle. (3) Remove wheel and tire assembly. (4) Remove brake caliper, adapter and rotor (Fig.
18).
Fig.20AXLESHAFTC-LOCK
1 - C-LOCK 2 - AXLE SHAFT 3 - SIDE GEAR
(8) Remove axle shaft (Fig. 21) carefully to prevent damage to the shaft bearing and seal in the axle tube.
Fig.18REARROTOR
1 - ROTOR 2 - CALIPER ADAPTER 3 - CALIPER
(5) Remove differential housing cover and drain
lubricant.
(6) Rotate differential case so pinion mate shaft lock screw is accessible. Remove lock screw and pin- ion mate shaft from differential case (Fig. 19).
Fig.21AXLESHAFT
1 - AXLE SHAFT 2 - SUPPORT PLATE 3 - CALIPER 4 - PARK BRAKE SHOE ASSEMBLY
INSTALLATION
Fig.19PINIONMATESHAFTLOCKSCREW
1 - LOCK SCREW 2 - PINION MATE SHAFT
(1) Lubricate bearing bore and seal lip with gear
(2) Insall axle shaft and engage into side gear
lubricant.
splines.
NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal.
(7) Push axle shaft inward and remove axle shaft
C-lock from the axle shaft (Fig. 20).
(3) Insert C-lock in end of axle shaft then push
axle shaft outward to seat C-lock in side gear.
REAR AXLE - 9 1/4
3 - 84
AXLE SHAFTS (Continued)(4) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(5) Align hole in shaft with hole in the differential lock screw with Loctitet on the
case and install threads. Tighten lock screw to 11 N·m (8 ft. lbs.).
(6) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
(7) Install brake rotor, caliper adapter and caliper. (8) Install wheel and tire. (9) Remove support and lower vehicle.
AXLE SHAFT SEALS REMOVAL
(1) Remove axle shaft. (2) Remove axle shaft seal (Fig. 22) from the axle
tube with a small pry bar.
Fig.22AXLESHAFTSEAL
1 - AXLE SEAL 2 - AXLE BEARING
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Coat the lip of the new seal with axle lubricant and install a seal with Installer C-4076-B and Han- dle C-4735-1.
DR
(4) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
AXLE BEARINGS REMOVAL
(1) Remove axle shaft. (2) Remove axle shaft seal from axle tube with a
small pry bar.
NOTE: The seal and bearing can be removed at the same time with the bearing removal tool.
(3) Remove axle
shaft bearing with Bearing
Remover 6310 and Foot 6310-9 (Fig. 23).
Fig.23AXLESHAFTBEARINGREMOVER
1 - AXLE SHAFT TUBE 2 - NUT 3 - GUIDE PLATE 4 - GUIDE 5 - THREADED ROD 6 - ADAPTER 7 - FOOT
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install axle shaft bearing with Installer C-4198
and Handle C-4171. Drive bearing in until tool con- tacts the axle tube.NOTE: When tool contacts the axle tube, the seal is installed to the correct depth.
(3) Install the axle shaft.
NOTE: Bearing is installed with the bearing part number against the installer.
DR AXLE BEARINGS (Continued)
(3) Coat the lip of the new axle seal with axle lubricant and install with Installer C-4076-B and Handle C-4735-1.
NOTE: When tool contacts the axle tube, the seal is installed to the correct depth.
(4) Install the axle shaft. (5) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
PINION SEAL REMOVAL
(1) Mark universal
joint, companion flange and
pinion shaft for installation reference.
(2) Remove propeller shaft from the companion
flange.
(3) Remove the brake rotors to prevent any drag. (4) Rotate companion flange three or four times and record pinion rotating torque with an inch pound torque wrench.
(5) Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes.
(6) Hold the companion flange with Holder 6719A
and remove pinion nut and washer.
(7) Remove companion flange with Remover C-452
(Fig. 24).
REAR AXLE - 9 1/4
3 - 85
(8) Remove pinion seal with pry tool or slide-ham-
mer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install new pinion seal with Installer C-3860-A
and Handle C-4171 (Fig. 25)
Fig.25PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER 3 - HOUSING
(3) Install companion flange on the end of the
shaft with the reference marks aligned.
(4) Install two bolts into the threaded holes in the
companion flange, 180° apart.
(5) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange.
(6) Install companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Install pinion washer and a new pinion nut.
The convex side of the washer must face outward.
CAUTION: Never exceed the minimum tightening torque 285 N·m (210 ft. lbs.) when installing the companion flange retaining nut at this point. Dam- age to collapsible spacer or bearings may result.
(8) Hold companion flange with Holder 6719 and tighten the pinion nut with a torque set to 285 N·m (210 ft. lbs.) (Fig. 26). Rotate pinion several revolu- tions to ensure the bearing rollers are seated.
(9) Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the read- ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 27).Fig.24COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PULLER
REAR AXLE - 9 1/4
3 - 86
PINION SEAL (Continued)DR
(10) If rotating torque is low, use Holder 6719 to hold the companion flange and tighten pinion nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved.
NOTE: The bearing rotating torque should be con- stant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition.
NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 N·m (210 ft. lbs.).
(11) Install propeller shaft with the installation
reference marks aligned.
(12) Tighten the companion flange bolts to 108
N·m (80 ft. lbs.).
(13) Install brake rotors. (14) Check the differential lubricant level.
Fig.26TIGHTENINGPINIONNUT
1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH
Fig.27PINIONROTATIONTORQUE
1 - COMPANION FLANGE 2 - TORQUE WRENCH
CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed.
DIFFERENTIAL DESCRIPTION
The differential case is a one-piece design. The dif- ferential pinion mate shaft is retained with a threaded pin. Differential bearing preload and ring gear backlash are set and maintained by threaded adjusters at the outside of the differential housing. Pinion bearing preload is set and maintained by the use of a collapsible spacer. The removable differential cover provides a means for inspection and service.
OPERATION
During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 28).
When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 29). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.
REMOVAL
(1) Remove filler plug from the differential cover.
DR DIFFERENTIAL (Continued)
REAR AXLE - 9 1/4
3 - 87
Fig.28DIFFERENTIAL-STRAIGHTAHEADDRIVING 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE
Fig.30REFERENCEMARKS
1 - REFERENCE MARKS 2 - REFERENCE MARK 3 - BEARING CAPS
(7) Remove bearing threaded adjuster lock from
each bearing cap.
(8) Loosen differential bearing cap bolts. (9) Loosen differential bearing adjusters through
the axle tubes with Wrench C-4164 (Fig. 31).
Fig.29DIFFERENTIAL-ONTURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
(2) Remove differential cover and drain the lubri-
cant.
(3) Clean housing cavity with flushing oil,
engine oil or a lint free cloth.
light
Fig.31THREADEDADJUSTERTOOL
NOTE: Do not use steam, kerosene or gasoline to clean the housing.
1 - AXLE TUBE 2 - BACKING PLATE 3 - THREAD ADJUSTER WRENCH
(4) Remove axle shafts. (5) Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the dif- ferential case.
(6) Mark differential housing and bearing caps for
installation reference (Fig. 30).
(10) Hold differential case while removing bearing
caps and adjusters.
(11) Remove differential case.
NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.
REAR AXLE - 9 1/4
3 - 88
DIFFERENTIAL (Continued) DISASSEMBLY(1) Remove pinion shaft lock screw (Fig. 32).
Fig.32SHAFTLOCKSCREW
1 - LOCK SCREW 2 - PINION SHAFT
(2) Remove pinion shaft. (3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 33).
DR
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion and thrust washers. (3) Install the pinion shaft. (4) Align the hole in the pinion shaft with the hole in the differential case and install the pinion shaft lock screw.
(5) Lubricate all differential
components with
hypoid gear lubricant.
INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position.
(2) Install differential assembly into the housing. (3) Install differential bearing caps in their origi-
nal locations (Fig. 34).
Fig.34BEARINGCAPS
1 - REFERENCE MARKS 2 - REFERENCE MARKS 3 - ADJUSTER LOCK 4 - BEARING CAP
(4) Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.
(5) Perform the differential bearing preload and
adjustment procedure.
Fig.33DIFFERENTIALGEARS
1 - THRUST WASHER 2 - SIDE GEAR 3 - DIFFERENTIAL PINION
(4) Remove differential side gears and thrust
washers.
NOTE: Be sure that all bearing cap bolts are tight- ened to their final torque of 136 N·m (100 ft.lbs.) before proceeding.
(6) Install axle shafts. (7) Apply a 1/4 inch bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 35).
DR DIFFERENTIAL (Continued)
REAR AXLE - 9 1/4
3 - 89
erated by the side gears as torque is applied through the ring gear (Fig. 36).
Fig.35COVERSEALANT
1 - SEALANT 2 - DIFFERENTIAL COVER
CAUTION: If cover is not installed within 3 to 5 min- utes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
(8) Install the cover and any identification tag and
tighten cover bolts to 41 N·m (30 ft. lbs.).
(9) Fill differential with lubricant to bottom of the fill plug hole. Refer to the Lubricant Specifications for the correct quantity and type.
NOTE: Trac-lok™ differential equipped vehicles should be road tested by making 10 to 12 slow fig- ure-eight turns. This maneuver will pump the lubri- cant through the clutch discs to eliminate a possible chatter noise complaint.
DIFFERENTIAL-TRAC-LOK DESCRIPTION
The optional Trac-Lokt differential case has a one- piece design and the similar internal components as a standard differential, plus two clutch disc pack- s.The differential pinion mate shaft is retained with a threaded pin. Differential bearing preload and ring gear backlash are set and maintained by threaded adjusters at the outside of the differential housing. Pinion bearing preload is set and maintained by the use of a collapsible spacer. The removable differential cover provides a means for inspection and service.
OPERATION
This differential clutches are engaged by two con- current forces. The first being the preload force exerted through Belleville spring washers within the clutch packs. The second is the separating forces gen-
Fig.36TRAC-LOKLIMITEDSLIPDIFFERENTIAL
1 - CASE 2 - RING GEAR 3 - DRIVE PINION 4 - PINION GEAR 5 - MATE SHAFT 6 - CLUTCH PACK 7 - SIDE GEAR 8 - CLUTCH PACK
This design provides the differential action needed for turning corners and for driving straight ahead during periods of unequal traction. When one wheel looses traction, the clutch packs transfer additional torque to the wheel having the most traction. This differential resist wheel spin on bumpy roads and provide more pulling power when one wheel looses traction. Pulling power is provided continuously until both wheels loose traction. If both wheels slip due to unequal traction, Trac-lokt operation is normal. In extreme cases of differences of traction, the wheel with the least traction may spin.
DIAGNOSIS AND TESTING
The most common problem is a chatter noise when turning corners. Before removing the unit for repair, drain, flush and refill the axle with the specified lubricant. A container of Mopar Trac-lokt Lubricant
REAR AXLE - 9 1/4
3 - 90
DIFFERENTIAL-TRAC-LOK (Continued)(friction modifier) should be added after repair ser- vice or during a lubricant change.
After changing the lubricant, drive the vehicle and make 10 to 12 slow, figure-eight turns. This maneu- ver will pump lubricant through the clutches. This will correct the condition in most instances. If the chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
DR
The differential can be tested without removing the differential case by measuring rotating torque. Make sure brakes are not dragging during this measure- ment.
(1) Place blocks in front and rear of both front
wheels.
the ground.
ing brake off.
(2) Raise one rear wheel until it is completely off
(3) Engine off, transmission in neutral, and park-
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 37).
Fig.37ROTATINGTORQUETEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE 2 - TORQUE WRENCH
(6) If rotating torque is less than 41 N·m (30 ft. lbs.) or more than 271 N·m (200 ft. lbs.) on either wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Fixture 6965 in a vise and position the
differential case on the fixture (Fig. 38).
(2) Remove ring gear if the ring gear is to be
(3) Remove pinion gear mate shaft lock screw. (4) Remove pinion gear mate shaft with a drift and
replaced.
hammer.
Fig.38DIFFERENTIALCASEFIXTURE
1 - HOLDING FIXTURE 2 - VISE 3 - DIFFERENTIAL
(5) Install and lubricate Step Plate C-6960-3 (Fig.
39).
Fig.39STEPPLATE
1 - LOWER SIDE GEAR 2 - DIFFERENTIAL CASE 3 - DISC
(6) Assemble Threaded Adapter C-6960-1 into top side gear. Thread Forcing Screw C-6960-4 into adapter until it becomes centered in adapter plate.
DR DIFFERENTIAL-TRAC-LOK (Continued)
REAR AXLE - 9 1/4
3 - 91
(7) Position a small
in slot of Threaded Adapter Disc C-6960-1 (Fig. 40) to prevent adapter from turning.
screw driver
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 42).
Fig.40THREADADAPTERDISC
1 - THRUST WASHER 2 - FEELER GAUGE
Fig.42PINIONGEARTHRUSTWASHER
1 - SOCKET 2 - SLOT IN DISC 3 - SCREWDRIVER 4 - LOWER DISC 5 - THREADED ROD 6 - UPPER DISC
(8) Install Forcing Screw C-6960-4 and tighten screw to 122 N·m (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 41).
Fig.41COMPRESSBELLEVILLESPRING
1 - TORQUE WRENCH 2 - FORCING SCREW 3 - DIFFERENTIAL CASE
(10) Insert Turning Bar C-6960-2 into the pinion
mate shaft hole in the case.
(11) Loosen Forcing Screw in small
increments until clutch pack tension is relieved. Then turn the case with the turning bar (Fig. 43).
Fig.43TURNINGBAR
1 - PINION GEARS 2 - TURNING BAR
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
REAR AXLE - 9 1/4
3 - 92
DIFFERENTIAL-TRAC-LOK (Continued)DR
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal (Fig. 44).
Fig.45CLUTCHDISCPACK
1 - CLUTCH PACK 2 - RETAINER 3 - SIDE GEAR 4 - RETAINER
Fig.44SIDEGEARSANDCLUTCHDISCS
1 - DIFFERENTIAL CASE 2 - RETAINER 3 - SIDE GEAR AND CLUTCH DISC PACK
(16) Remove differential case from the Holding Fixture. Remove side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no grooves or lines) must be presoaked in Friction Modifier before assembly. Soak plates and discs for a minimum of 20 minutes.
(1) Lubricate each component with gear lubricant
before assembly.
(2) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 45).
(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 46).
NOTE: Verify clutch pack retaining clips are in posi- tion and seated in the case pockets.
(5) Position case on the Fixture 6965.
Fig.46CLUTCHPACKANDLOWERSIDEGEAR
1 - DIFFERENTIAL CASE 2 - LOWER SIDE GEAR AND CLUTCH PACK
DR DIFFERENTIAL-TRAC-LOK (Continued)
REAR AXLE - 9 1/4
3 - 93
(6) Install lubricated Step Plate C-6960-3 in lower
(14) Remove forcing screw, step plate and threaded
(7) Install upper side gear and clutch disc pack
(15) Install pinion gear mate shaft and align holes
side gear.
(Fig. 47).
adapter.
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE BEARINGS
