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+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 REMOVAL
(1) Remove differential case from axle housing. (2) Remove differential bearings from the case with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 48).Fig.48DIFFERENTIALBEARINGPULLER
1 - PULLER 2 - ADAPTERS 3 - BEARING 4 - DIFFERENTIAL 5 - PLUG
Fig.47CLUTCHPACKANDUPPERSIDEGEAR
1 - SIDE GEAR AND CLUTCH PACK 2 - DIFFERENTIAL CASE 3 - LOWER DISC
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in side gears and verify
pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until pinion mate shaft holes in pinion gears align with holes in case.
NOTE: screw in order to install the pinion gears.
If necessary, slightly tighten the forcing
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to ver- ify alignment.
REAR AXLE - 9 1/4
3 - 94
DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION(1) Install differential side bearings with Installer
C-4213 and Handle C-4171 (Fig. 49).
DR
Fig.50RINGGEAR
1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER
(8) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(9) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
companion flange with Remover
(11) Remove C-452 (Fig. 51).
Fig.49DIFFERENTIALCASEBEARING
1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER
(2) Install differential case into housing.
PINION GEAR/RING GEAR/ TONE RING REMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replac- ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts. (4) Remove differential from the differential hous-
ing.
case.
jaw protectors..
(5) Place differential case in a vise with soft metal
(6) Remove ring gear bolts from the differential
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 50).
Fig.51COMPANIONFLANGE
1 - COMPANION FLANGE 2 - REMOVER
(12) Remove pinion gear from the housing (Fig.
52).
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 95
(16) Remove rear pinion bearing cup from housing (Fig. 54) with Remover C-4307 and Handle C-4171.
Fig.52PINIONGEAR
1 - RAWHIDE HAMMER
(13) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
(14) Remove front pinion bearing and oil slinger if
equipped.
(15) Remove
front
pinion bearing
cup with
Remover C-4345 and Handle C-4171 (Fig. 53).
Fig.54REARPINIONBEARINGCUP
1 - DRIVER 2 - HANDLE
(17) Remove collapsible spacer from the pinion
shaft (Fig. 55).
Fig.53FRONTPINIONBEARINGCUP
1 - REMOVER 2 - HANDLE
Fig.55COLLAPSIBLESPACER
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
REAR AXLE - 9 1/4
3 - 96
PINION GEAR/RING GEAR/TONE RING (Continued)DR
(18) Remove rear pinion bearing (Fig. 56) from the pinion shaft with Puller C-293-PA and Adapters C-293-37.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a matched set. Do not replace one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjust- ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent stick lubricant to outside surface of the pinion bearing cups.
(2) Install rear pinion bearing cup (Fig. 58) with Installer C-4308 and Driver Handle C-4171 and ver- ify cup is seated.
Fig.56REARPINIONBEARING
1 - PULLER 2 - VISE 3 - ADAPTERS 4 - PINION SHAFT
(19) Remove pinion depth shim (Fig. 57) from the
pinion shaft and record shim thickness.
Fig.58REARPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
(3) Install front pinion bearing cup (Fig. 59) with Installer D-129 and Handle C-4171 and verify cup is seated.
(4) Lubricate and install front pinion bearing into
the housing.
(5) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 60).
Fig.57PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 97
Fig.59FRONTPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
Fig.61PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
Fig.60PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER 3 - HOUSING
(6) Install pinion depth shim (Fig. 61) on the pin-
ion gear shaft.
(7) Install rear bearing on the pinion (Fig. 62) with
Installer C-3095-A and a press.
Fig.62REARPINIONBEARING
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
REAR AXLE - 9 1/4
3 - 98
PINION GEAR/RING GEAR/TONE RING (Continued)(8) Install a new collapsible spacer on the pinion
shaft (Fig. 63).
DR
Fig.64PINIONNUT
1 - DIFFERENTIAL HOUSING 2 - HOLDER 3 - TORQUE WRENCH
(16) Check pinion rotating torque with an inch pound torque wrench (Fig. 65). The pinion rotating torque should be: † Original Bearings: 1 to 3 N·m (10 to 20 in. lbs.). † New Bearings: 2 to 5 N·m (15 to 35 in. lbs.).
Fig.63COLLAPSIBLESPACER
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
(9) Lubricate rear pinion bearing and install pin-
ion gear into the housing.
C-3718 and Holder 6719.
(10) Install
companion flange with Installer
(11) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(12) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
(13) Install companion flange washer and a new nut on the pinion and tighten the nut until there is zero bearing end-play.
(14) With a torque wrench tighten the nut to 285
N·m (210 ft. lbs.) (Fig. 64).
CAUTION: Never loosen pinion nut to decrease pin- ion rotating torque and never exceed specified pre- load torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure pinion rotating torque frequently to avoid over crushing the collapsible spacer.
Fig.65PINIONROTATIONTORQUE
1 - COMPANION FLANGE 2 - TORQUE WRENCH
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 99
(17) Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position.
(18) Position ring gear on the differential case and start two ring gear bolts. This will provide case-to- ring gear bolt hole alignment.
(19) Invert the differential case in the vise. (20) Install new ring gear bolts and alternately
tighten to 156 N·m (115 ft. lbs.) (Fig. 66).
CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.
(21) Install differential in housing and verify gear
mesh, backlash and contact pattern.
(22) Install axle shafts. (23) Install differential cover and fill with gear
(24) Install propeller shaft with reference marks
lubricant.
aligned.
Fig.66RINGGEARBOLTS
1 - TORQUE WRENCH 2 - RING GEAR BOLTS 3 - RING GEAR 4 - DIFFERENTIAL CASE
3 - 100
REAR AXLE - 10 1/2 AA
REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page
DR
page
REAR AXLE - 10 1/2 AA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 100
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 104
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 108
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 108AXLE SHAFTS
REMOVAL INSTALLATION AXLE BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . . . . . . . . . . 111OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 114
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 115
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117DIFFERENTIAL TRAC-RITE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 118
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 120DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121PINION SEAL
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123DIFFERENTIAL DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . 114
REAR AXLE - 10 1/2 AA DESCRIPTION
The axle consists of a cast iron center casting dif- ferential housing with axle shaft tubes extending from each side. The tubes are pressed into the differ- ential housing and welded. The design has the cen- terline of the pinion set below the centerline of the ring gear. The axle is a full floating axle where the loads are supported by the axle housing tubes. The axle has a vent used to relieve internal pressure caused by lubricant vaporization and internal expan- sion.
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.
DR REAR AXLE - 10 1/2 AA (Continued) 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 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
caused by a:
Vibration at the rear of the vehicle is usually † Damaged drive shaft. † Missing drive shaft balance weight(s).
REAR AXLE - 10 1/2 AA
3 - 101
† Worn or out-of-balance wheels. † Loose wheel lug nuts. † Worn U-joint(s). † 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.
DIAGNOSTIC CHART
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.
REAR AXLE - 10 1/2 AA
3 - 102
REAR AXLE - 10 1/2 AA (Continued)DR
Condition
Possible Causes
Correction
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.
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. 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.
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.
2. Fill differential with the correct fluid type and quantity. 3. Re-adjust bearing pre-loads. 4. Re-adjust ring gear backlash.
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 103
Condition
Possible Causes
Correction
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.
REMOVAL
INSTALLATION
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.
(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
(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
(3) Install shock absorbers to axle and tighten to
housing.
brackets.
and axle vent hose.
(6) Remove brake hose at the axle junction block
(4) Install the RWAL sensor to the differential
(7) Disconnect parking brake cables and cable
(5) Connect the parking brake cables and cable
(8) Remove brake calipers and rotors. (9) Mark propeller shaft and companion flange for
(6) Install brake calipers. (7) Connect brake hose to the axle junction block
installation alignment reference.
(10) Remove propeller shaft. (11) Remove shock absorbers from axle. (12) Remove U-bolts from axle. (13) Separate the axle from the vehicle.
and axle vent hose.
(8) Align propeller shaft and pinion companion flange reference marks and tighten companion flange bolts to 115 N·m (85 ft. lbs.).
(9) Install the wheels and tires.
(110 ft. lbs.).
specification.
housing.
brackets.
DR
ing torque should be 1.7-2.26 N·m (15-20 in. lbs.) (Fig. 1).
REAR AXLE - 10 1/2 AA
3 - 104
REAR AXLE - 10 1/2 AA (Continued)(10) Fill differential to specifications. (11) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched sets only. Compensation for pinion depth variance is achieved with a select shim. The shim is located between the rear pinion bearing and the pinion gear head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT 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. 1).
Fig.2PINIONHEIGHTBLOCK
1 - PINION BLOCK 2 - PINION HEIGHT BLOCK
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 3).
(5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 165 N·m (122 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
Fig.3GAUGETOOLSINHOUSING
1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on the pinion height block. Hold scooter block and zero the dial indicator.
Fig.1PINIONGEARDEPTHGAUGETOOLS
1 - DIAL INDICATOR 2 - ARBOR 3 - PINION HEIGHT BLOCK 4 - CONE 5 - SCREW 6 - PINION BLOCK 7 - SCOOTER BLOCK 8 - ARBOR DISC
(1) Assemble Pinion Height Block 6739, Pinion Block 8899 and rear pinion bearing onto Screw 6741
(Fig. 1).(2) Insert assembled height gauge components, rear bearing and screw into the housing through pin- ion bearing cups (Fig. 2).
(3) Install
front pinion bearing and install the Cone-nut 6740 hand tight. Then check tool rotating torque with an inch pound torque wrench. The rotat-
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 105
(8) Slowly slide the scooter block across the pinion height block over to the arbor (Fig. 4). Move the scooter block till dial indicator crests the arbor, then record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
Fig.4PINIONGEARDEPTHMEASUREMENT
1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR
DIFFERENTIAL CASE BEARING PRELOAD AND GEAR BACKLASH
Fig.5ADJUSTERLOCKBOLT
1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT 4 - BEARING CAP BOLT
Backlash is adjusted by moving the adjusters in and out or both. By moving the adjusters the case/ ring gear will move closer or further away from the pinion. In most cases this adjustment can be used to achieve the correct gear tooth pattern and set the case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps. (3) Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 (Fig. 6) until they make contact with the differ- ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear
