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FRONT AXLE - 9 1/4 AA . . . . . . . . . . . . . . . . . . . 45REAR AXLE - 9 1/4
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REAR AXLE - 10 1/2 AA . . . . . . . . . . . . . . . . . . 100
REAR AXLE - 11 1/2 AA . . . . . . . . . . . . . . . . . . 127PROPELLER SHAFT
TABLE OF CONTENTS
page
page
PROPELLER SHAFT
. . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLSFRONT PROPELLER SHAFT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTMENTSSINGLE CARDAN UNIVERSAL JOINTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9REAR PROPELLER SHAFT
REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT DIAGNOSIS AND TESTING
PROPELLER SHAFT VIBRATION
Tires that are out-of-round or wheels that are
unbalanced, will cause a low frequency vibration.
Brake drums that are unbalanced will cause a
harsh, low frequency vibration.
Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle speed is increased. A vibration that occurs within a specific speed range is not usually caused by a pro- peller shaft being unbalanced. Defective universal joints or an incorrect propeller shaft angle are usu- ally the cause of such a vibration.
PROPELLER SHAFT
3 - 2
PROPELLER SHAFT (Continued)DRIVELINE VIBRATION
DR
Drive Condition
Possible Cause
Correction
Propeller Shaft Noise
1) Undercoating or other foreign material on shaft. 2) Loose U-joint clamp screws.
3) Loose or bent U-joint yoke or excessive runout. 4) Incorrect driveline angularity.
5) Rear spring center bolt not in seat. 6) Worn U-joint bearings. 7) Propeller shaft damaged or out of balance. 8) Broken rear spring. 9) Excessive runout or unbalanced condition. 10) Excessive drive pinion gear shaft runout. 11) Excessive axle yoke deflection.
12) Excessive transfer case runout.
Universal Joint Noise
1) Loose U-joint clamp screws.
2) Lack of lubrication.
1) Clean exterior of shaft and wash with solvent. 2) Install new clamps and screws and tighten to proper torque. 3) Install new yoke.
4) Measure and correct driveline angles. 5) Loosen spring u-bolts and seat center bolt. 6) Install new U-joint. 7) Installl new propeller shaft.
8) Install new rear spring. 9) Re-index propeller shaft, test, and evaluate. 10) Re-index propeller shaft and evaluate. 11) Inspect and replace yoke if necessary. 12) Inspect and repair as necessary.
1) Install new clamps and screws and tighten to proper torque. 2) Replace as U-joints as necessary.
PROPELLER SHAFT BALANCE
NOTE: Removing and re-indexing the propeller shaft 180° relative to the yoke may eliminate some vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle. (2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the pro- peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are cor- rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque. (6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90° apart.
(8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 1). (10) Start the engine and re-check for vibration. If there is little or no change in vibration, move the clamp to one of the other three positions. Repeat the vibration test.
(11) If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft.
(12) If the vibration decreased, clamp (Fig. 2) and repeat the test.
install a second
(13) If the additional clamp causes an additional vibration, separate the clamps (1/2 inch above and below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen.
DR PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 3
(15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle.
PROPELLER SHAFT RUNOUT
Fig.1CLAMPSCREWATPOSITION1
1 - CLAMP 2 - SCREWDRIVER
(1) Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the shaft sufficiently far away from weld areas to ensure that the effects of the weld process will not enter into the measurements.
(4) Refer to Runout Specifications chart. (5) If the propeller shaft runout is out of specifica- tion, remove the propeller shaft, index the shaft 180°, and re-install the propeller shaft. Measure shaft runout again.
(6) If the propeller shaft runout is now within specifications, mark the shaft and yokes for proper orientation.
(7) If the propeller shaft runout is not within spec- ifications, verify that the runout of the transmission/ transfer case and axle are within specifications. Correct as necessary and re-measure propeller shaft runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Fig.2TWOCLAMPSCREWS
0.020 in. (0.50 mm) 0.025 in. (0.63 mm) 0.020 in. (0.50 mm)
Front of Shaft Center of Shaft Rear of Shaft note: Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft tube for tube lengths over 30 inches. For tube lengths under 30 inches, the maximum allowed runout is 0.020 in. (0.50 mm) for the full length of the tube.STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
Fig.3CLAMPSCREWSSEPARATED
1 - 1⁄2 INCH
This procedure applies to both the front/rear pro- peller shafts. To obtain the front output angle (A) on the front propeller shaft, place the inclinometer the machined surface of the C/V joint.
(1) To check driveline alignment, raise and support the vehicle at the axles as level as possible. Allow the wheels and propeller shaft to turn.
(2) Remove any external bearing snap rings,
if equipped from universal joint so protractor base sits flat.
PROPELLER SHAFT
3 - 4
PROPELLER SHAFT (Continued)DR
(3) Rotate the shaft until
transmission/transfer
case output yoke bearing is facing downward.
NOTE: Always make measurements from front to rear and from the same side of the vehicle.
(4) Place Inclinometer 7663 on yoke bearing (A) parallel to the shaft (Fig. 4). Center bubble in sight glass and record measurement.
This measurement will give you the transmis-
sion yoke Output Angle (A).
Fig.4OUTPUTANGLE(A)
(5) Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft (Fig. 5). Center bubble in sight glass and record mea- surement. This measurement can also be taken at the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(6) Rotate propeller shaft 90 degrees and place Inclinometer on companion flange yoke bearing par- allel to the shaft (Fig. 6). Center bubble in sight glass and record measurement.
This measurement will give you the pinion
Companion Flange Input Angle (B).
(7) Subtract smaller figure from larger (C minus to obtain Transmission/Transfer Case Output
A) Operating Angle.
(8) Subtract smaller figure from larger (C minus
B) to obtain axle Input Operating Angle.
Fig.5PROPELLERSHAFTANGLE(C)
Fig.6INPUTANGLE(B)
7) for additional information.
Refer to rules given below and the example in (Fig. † Good cancellation of U-joint operating angles † Operating angles should be less than 3°. † At least 1/2 of one degree continuous operating
should be within 1°.
(propeller shaft) angle.
DR PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 5
1 - 4.9° Angle (C) 2 - 3.2° Angle (B) 3 - Input Yoke
Fig.7UNIVERSALJOINTANGLEEXAMPLE
4 - 3.0° Angle (A) 5 - Output Yoke
TWO-PIECE PROPELLER SHAFT
The procedure to measure the propeller shaft angles involved with a two-piece (Fig. 8) propeller shaft is the same as those for a one-piece propeller shaft.
1 - YOKES MUST BE IN SAME PLANE
Fig.8UNIVERSALJOINTANGLE
PROPELLER SHAFT
3 - 6
PROPELLER SHAFT (Continued) SPECIFICATIONSDR
DESCRIPTION
Center Bearing Bolts
Front Pinion Flange Bolts Rear Pinion Flange Bolts
SPECIAL TOOLS
TORQUE SPECIFICATIONS
N·m 54
115
115Ft. Lbs.
In. Lbs.
40
85
85FRONT PROPELLER SHAFT REMOVAL
INCLINOMETER7663
BearingSplitter1130
INSTALLER6052
(1) Position transmission and transfer case into
neutral.
(2) Raise and support vehicle. (3) Remove exhaust crossover pipe. (4) Mark a line across the axle companion flange and propeller shaft flange yoke (Fig. 9) for installa- tion reference.
Fig.9COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PROPELLER SHAFT 3 - FLANGE YOKE 4 - REFERENCE MARK
(5) Remove companion flange bolts. (6) Remove dust boot clamp (Fig. 10) from the C/V
jonit end of the shaft.
(7) Remove propeller shaft.
DR FRONT PROPELLER SHAFT (Continued)
PROPELLER SHAFT
3 - 7
Fig.10DUSTBOOT
Fig.11COMPANIONFLANGE
1 - C/V JOINT 2 - TRANSFER CASE 3 - BOOT CLAMP 4 - PROPELLER SHAFT
INSTALLATION
1 - PROPELLER SHAFT 2 - COMPANION FLANGE 3 - REFERENCE MARK 4 - SHAFT FLANGE YOKE
(1) Install propeller shaft with with all reference
marks aligned.
(2) Install transfer case companion flange bolts
and tighten to 30.5 N·m (22.5 ft. lbs.).
(3) Install axle companion flange bolts and tighten
to 108 N·m (80 ft. lbs.).
(4) Install skid plate, if equipped. (5) Lower vehicle and road test to verify repair.
REAR PROPELLER SHAFT REMOVAL
(1) Shift transmission into Neutral. (2) Raise and support vehicle. (3) Mark a line across the pinion companion flange and propeller shaft flange yoke (Fig. 11) for installa- tion reference.
(4) Mark the outline of the center bearing (Fig. 12) if
on the crossmember for installation reference, equipped.
(5) Remove center bearing mounting nuts,
equipped.
(6) Remove pinion yoke companion flange bolts. (7) Slide slip yoke off of the transmission or trans-
fer case output shaft and remove propeller shaft.
if
Fig.12CENTERBEARING
1 - CENTER BEARING 2 - DUST BOOT 3 - MOUNTING NUTS
PROPELLER SHAFT
3 - 8
REAR PROPELLER SHAFT (Continued) INSTALLATIONDR
(1) Slide the slip yoke onto the transmission/trans-
fer case output shaft.
(2) Align and install center bearing on crossmem- ber, if necessary and tighten nutts to 54 N·m (40 ft. lbs.).
(3) Align reference marks on the propeller shaft
yoke and pinion companion flange (Fig. 13).
(4) Tighten pinion companion flange bolts to 115
N·m (85 ft. lbs.).
Fig.14REFERENCEMARKS
1 - REFERENCE MARK 2 - CENTER BEARING 3 - BOOT CLAMP 4 - DUST BOOT
INSTALLATION
NOTE: Two types of center bearings are used and are not interchangeable. Install the same type as the vehicle was built with.
Fig.13REARPROPELLERSHAFT
1 - COMPANION FLANGE 2 - PROPELLER SHAFT
(5) Lower the vehicle.
CENTER BEARING REMOVAL
(1) Remove rear propeller shaft. (2) Mark the two shafts (Fig. 14) for installation
(3) Remove slip joint boot clamp and separate the
reference.
two shafts.
(4) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(5) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during removal of center bearing.
(6) Set shaft in press and press bearing off the
shaft.
(1) Install new slinger on shaft and drive into posi-
tion with appropriate installer tool.
(2) Install new center bearing on shaft with Bear- ing Installer Tool 6052. Drive on shaft with hammer until bearing is seated.
(3) Clean shaft splines and apply a coat of multi-
purpose grease.
(4) Align master splines and slide front and rear half-shafts together. Reposition slip yoke boot and install new clamp.
(5) Install propeller shaft in vehicle.
ADJUSTMENTS
CENTER BEARING
Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two- piece propeller shaft. To decrease shudder, lower the center bearing in 1/8 inch increments. Use shim stock or fabricated plates. Plate stock must be used to maintain compression of the rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts.
DR
PROPELLER SHAFT
3 - 9
SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY
NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the compan- ion yoke after removing the cardan joint from the tube yoke.
Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly.
(1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 15).
Fig.16PressOutBearing
1 - PRESS 2 - SOCKET
(7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole. Then, carefully press the end of the cross until the remaining bearing cap can be removed (Fig. 17).
If
the cross or bearing cap are not CAUTION: straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.
ASSEMBLY
NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the compan- ion yoke after removing the cardan joint from the tube yoke.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores to aid in installa- tion.Fig.15SnapRing
1 - SNAP RING
(4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. if
(5) Position the yoke with the grease fitting,
equipped, pointing up.
(6) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and press the cap through the yoke to release the lower bearing cap (Fig. 16).
PROPELLER SHAFT
3 - 10
SINGLE CARDAN UNIVERSAL JOINTS (Continued)DR
(3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 19). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly.
Fig.17PressOutRemainingBearing
1 - CROSS 2 - BEARING CAP
(2) Position the cross in the yoke with its lube fit-
ting, if equipped, pointing up (Fig. 18).
Fig.19InstallBearingOnTrunnion
1 - BEARING CAP 2 - TRUNNION
(4) Press the bearing cap into the yoke bore
enough to install a snap ring.
(5) Install a snap ring. (6) Repeat Step 3 and Step 4to install the opposite bearing cap. If the joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped. (8) Install the propeller shaft.
Fig.18CrossInYoke
1 - CROSS 2 - YOKE
DR
HALF SHAFT
3 - 11
HALF SHAFT
TABLE OF CONTENTS
page
page
HALF SHAFT
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLSCV JOINT-OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13CV JOINT-INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16HALF SHAFT CAUTION
CAUTION:: Never grasp half shaft assembly by the boots. This may cause the boot to pucker or crease and reduce the service life of the boot. Avoid over angulating or stroking the C/V joints when handling the half shaft. Half shafts exposed to battery acid, transmission fluid, brake fluid, differential fluid or gasoline may cause the boots to deteriorate.
DIAGNOSIS AND TESTING
Check for grease at the inboard and outboard C/V
joint. This is a sign of boot or boot clamp damage.
NOISE/VIBRATION IN TURNS
A clicking noise or a vibration in turns could be caused by a damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss/contamination of the joint grease, resulting in inadequate lubrication of the joint. Noise could also be caused by another component of the vehicle com- ing in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of a damaged or worn C/V joint. A torn boot or loose/missing clamp on the inner/outer joint which has allowed the grease to be lost will damage the C/V joint.
SHUDDER/VIBRATION DURING ACCELERATION
This problem could be a result of a worn/damaged inner tripod joint or a sticking tripod joint. Improper wheel alignment may also cause a shudder or vibra- tion.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of out of balance front tires or tire/wheel runout. Foreign material (mud, etc.) packed on the backside of the wheel(s) will also cause a vibration.
REMOVAL
(1) Loosen lug nuts and hub nut while the with
the vehicle brakes applied.
(2) Raise and support the vehicle. (3) Remove wheel and tire assembly (4) Remove half shaft hub nut. (5) Remove brake caliper and rotor. (6) Position hydraulic jack under lower suspension
arm and raise jack to unload rebound bumper.
(7) Remove lower shock absorber bolt. (8) Remove upper ball joint nut and seperate ball
with Remover 8677 (Fig. 1).
Fig.1UPPERBALLJOINTSEPARATION
1 - UPPER CONTROL ARM 2 - REMOVER 3 - STEERING KNUCKLE
HALF SHAFT
3 - 12
HALF SHAFT (Continued)DR
(9) Disengage inner C/V joint from the axle shaft snap-ring by apply pressure with two pry bars between the C/V housing and axle housing.
(10) Tilt the knuckle out and push the half shaft
out of the knuckle (Fig. 2).
CAUTION: Do not damage outer C/V threads while removing half shaft.
Fig.2STEERINGKNUCKLE
1 - STEERING KNUCKLE 2 - SHOCK 3 - HALFSHAFT 4 - DISC BRAKE CALIPER 5 - HUB/BEARING
(11) Remove the half shaft from the vehicle.
INSTALLATION
(1) Clean hub bearing bore, hub bearing mating
surface and half shaft splines.
(2) Apply a light coating of grease to the front axle
shaft output splines.
(3) Install half shaft into the knuckle (Fig. 3).
Fig.3HALFSHAFTANDHUB/BEARING
1 - HUB/BEARING MOUNTING NUTS 2 - HALF SHAFT
(4) Install half shaft on the axle output shaft. Push firmly to engage the axle output shaft snap ring into the inner C/V housing.
(5) Install upper ball joint into the knuckle. (6) Install upper ball joint nut and tighten to spec-
ification.
specification.
(7) Install lower shock absorber bolt and tighten to
(8) Install brake rotor and caliper. (9) Install half shaft hub nut and tighten to 251
N·m (185 ft. lbs.).
(10) Install the wheel and tire assembly.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION Half Shaft Nut
N·m 251
Ft. Lbs.
185
In. Lbs.
SPECIAL TOOLS
CLAMPINSTALLERC-4975A
DR
CV JOINT-OUTER REMOVAL
HALF SHAFT
3 - 13
(1) Clamp shaft in a vise (with soft jaws) and sup-
(2) Remove clamps with a cut-off wheel or grinder
port C/V joint.
(Fig. 4).
CAUTION: Do not damage C/V housing or half shaft.
Fig.4BOOTCLAMPLOCATIONS
1 - C/V HOUSING 2 - CLAMP 3 - HALF SHAFT 4 - CLAMP 5 - C/V BOOT
Fig.5OUTERC/VJOINT
1 - SNAP RING 2 - SNAP RING GROVE 3 - SNAP RING PLIERS
(3) Slide the boot down the shaft. (4) Remove lubricant to expose the C/V joint snap
(5) Spread snap ring and slide the joint off the
ring.
shaft (Fig. 5).
(6) Slide boot off the shaft and discard old boot. (7) Mark alignment marks on the inner race/hub, bearing cage and housing with dabs of paint (Fig. 6). (8) Clamp C/V joint in a vertical position in a soft
jawed vise.
(9) Press down one side of the bearing cage to gain
access to the ball at the opposite side.
NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bear- ing cage with the drift.
(10) Remove ball from the bearing cage (Fig. 7). (11) Repeat step above until all six balls are
removed from the bearing cage.
(12) Lift cage and inner race upward and out from
the housing (Fig. 8).
(13) Turn inner race 90° in the cage and rotate the
inner race/hub out of the cage (Fig. 9).
Fig.6BEARINGACCESS
1 - ALIGNMENT MARKS 2 - BEARING HUB 3 - BEARING CAGE 4 - HOUSING
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint and boot.
(1) Clean all C/V joint components and shaft. (2) Apply a light coat of grease supplied with the joint/boot to the C/V joint components before assem- bling them.
(3) Align the inner race, cage and housing accord-
ing to the alignment reference marks.
(4) Insert the inner race into the cage (Fig. 10) and
rotate race into the cage.
(5) Rotate the inner race/hub in the cage (Fig. 11).
HALF SHAFT
3 - 14
CV JOINT-OUTER (Continued)DR
Fig.7BEARING
Fig.9INNERRACE/HUB
1 - HOUSING 2 - INNER RACE/HUB 3 - BEARING CAGE 4 - BALL
Fig.10INNERRACE/HUB
1 - INNER RACE/HUB 2 - BEARING CAGE
Fig.8CAGEANDINNERRACE/HUB
1 - HOUSING 2 - INNER RACE 3 - CAGE WINDOW
(6) Insert cage into the housing (Fig. 12). Rotate the cage 90° into the housing so the large bearing hub counterbore is facing outwards.
(7) Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races.
(8) Tilt inner race/hub and cage and install the
balls (Fig. 13).
(9) Place new clamps onto new boot and slide boot
onto the shaft to it’s original position.
(10) Apply the rest of grease to the C/V joint and
boot.
Fig.11CAGEANDINNERRACE/HUB
1 - CAGE WINDOWS 2 - SNAP RING
DR CV JOINT-OUTER (Continued)
HALF SHAFT
3 - 15
Fig.12BEARINGCAGEANDHOUSING
Fig.14OUTERC/VJOINT
1 - OUTER RACE 2 - BEARING CAGE WINDOW 3 - CV JOINT HOUSING
1 - SNAP RING 2 - SHAFT TAPER 3 - SNAP RING GROVE 4 - BEARING HUB
NOTE: Verify boot is not twisted and remove any excess air.
(13) Secure both boot clamps (Fig. 15) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed.
Fig.13BALLBEARING
1 - C/V HOUSING 2 - INNER RACE/HUB 3 - BEARING CAGE 4 - BEARING
(11) Install the joint onto the shaft. Push the joint onto the shaft until the snap ring seats in the groove (Fig. 14).
NOTE: Pull on the joint to verify the span ring has engaged.
(12) Position the boot on the joint in it’s original
position.
Fig.15BOOTCLAMPLOCATIONS
1 - C/V HOUSING 2 - CLAMP 3 - HALF SHAFT 4 - CLAMP 5 - C/V BOOT
3 - 16
HALF SHAFT
CV JOINT-INNER REMOVAL
DR
(1) Clamp shaft in a vise (with soft jaws) and sup-
(2) Remove clamps with a cut-off wheel or grinder
port C/V joint.
(Fig. 16).
CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder.
Fig.18TRIPODSNAPRING
1 - SNAP RING 2 - TRIPOD 3 - PLIERS
(6) Remove tripod and boot from the half shaft. (7) Clean and inspect C/V components for exces- sive wear and damage. Replace the tripod as a unit only if necessary.
INSTALLATION
(1) Clean all C/V joint components and shaft. (2) Slide new boot down the half shaft. (3) Install tripod and tripod snap ring on the half
shaft (Fig. 19).
Fig.16BOOTCLAMPLOCATION
1 - C/V HOUSING 2 - CLAMP 3 - BOOT 4 - CLAMP
(3) Remove housing from the half shaft (Fig. 17)
and slide boot down shaft.
Fig.19C/VTRIPOD
1 - BOOT 2 - TRIPOD
Fig.17C/VHOUSING
1 - BOOT 2 - HOUSING
(4) Remove housing bushing from the housing. (5) Remove tripod snap ring (Fig. 18).
(4) Pack grease supplied with the joint/boot into
the housing and boot.
(5) Coat tripod with supplied grease. (6) Install new bushing (Fig. 20) onto the housing. (7) Insert the tripod and shaft in the housing.
DR CV JOINT-INNER (Continued)
HALF SHAFT
3 - 17
Fig.20HOUSINGBUSHING
1 - BUSHING 2 - HOUSING
(8) Position the boot on the joint and shaft in it’s
original position (Fig. 21).
NOTE: Verify boot is not twisted and remove any excess air.
(9) Measure the distance from the end of the hous- ing to the end of the boot on the shaft. This measure- ment should be 260 mm (10.25 in.).
Fig.21INNERC/VBOOT
1 - CLAMP 2 - BOOT 3 - CLAMP 4 - SHAFT 5 - HOUSING
NOTE: If measurement is not correct, allow more or less air into the boot.
(10) Secure both boot clamps with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed.
3 - 18
FRONT AXLE - C205F
FRONT AXLE - C205F
TABLE OF CONTENTS
page
DR
page
FRONT AXLE - C205F
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 30AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT AXLE - C205F DESCRIPTION
The axle consists of an alumunum center section with an axle tube extending from one side. The tube is pressed into the differential housing. The power is transferred from the axle through two constant veloc- ity (C/V) drive shafts to the wheel hubs. The drive shafts are identical and interchangeable.
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, 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.
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35DIFFERENTIAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42When 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 mate shaft can also cause a snapping 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 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-
DR FRONT AXLE - C205F (Continued)
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: † Damaged drive shaft. † Missing drive shaft balance weight(s). † 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).
FRONT AXLE - C205F
3 - 19
Check for loose or damaged front end components or engine/transmission mounts. These components can contribute to what appears to be a rear end vibration. Do not overlook engine accessories, brack- ets and drive belts.
All driveline components
should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
into gear (or the clutch engaged) can be caused by:
A snap or clunk noise when the vehicle is shifted † 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.
2. Bent or sprung axle shaft. 3. End-play in pinion bearings.
4. Excessive gear backlash between the ring gear and pinion.
5. Improper adjustment of pinion gear bearings. 6. Loose pinion yoke nut. 7. Scuffed gear tooth contact surfaces.
1. Inspect axle tube alignment. Correct as necessary.
2. Inspect and correct as necessary. 3. Refer to pinion pre-load information and correct as necessary. 4. Check adjustment of the ring gear and pinion backlash. Correct as necessary. 5. Adjust the pinion bearings pre-load. 6. Tighten the pinion yoke nut. 7. Inspect and replace as necessary.
FRONT AXLE - C205F
3 - 20
FRONT AXLE - C205F (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 FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 21
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. 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) Place transmission in netural. (2) Raise and support the vehicle. (3) Remove tire and wheel assemblies. (4) Remove axle half shafts. (5) Remove exhaust crossover. (6) Mark front propeller shaft and remove shaft. (7) Remove
suspension crossmember mounting
bolts (Fig. 1) and remove crossmember. (8) Support axle with hydraulic jack. (9) Remove axle housing pinion mounting bolts
(1) Raise axle into position. (2) Install axle mounting bolts and tighten nuts to
95 N·m (70 ft. lbs.).
(3) Install
suspension crossmember and bolts.
Tighten crossmember nuts to 102 N·m (75 ft. lbs.).
(4) Install
front propeller shaft with reference marks aligned (Fig. 5) and tighten bolts to 115 N·m (85 ft. lbs.).
(5) Install exhaust crossover. (6) Install axle half shafts. (7) Check the differential fluid level and add fluid
(10) Remove axle shaft tube mounting bolts (Fig.
if necessary.
(11) Remove differential housing mounting bolts
(8) Install tire and wheel assemblies. (9) Remove support lower the vehicle.
(Fig. 2).
3).
(Fig. 4).
(12) Lower axle from the vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets only. The identifying numbers for the ring gear and
FRONT AXLE - C205F
3 - 22
FRONT AXLE - C205F (Continued)DR
Fig.1SUSPENSIONCROSSMEMBER
1 - PINION FLANGE 2 - AXLE TUBE MOUNTING BRACKET 3 - CROSSMEMBER BOLTS
Fig.3AXLETUBEMOUNT
1 - MOUNTING BOLTS 2 - BOLTS
Fig.2HOUSINGPINIONMOUNTINGBOLTS
1 - MOUNTING BOLTS 2 - PINION FLANGE
pinion are painted onto the pinion gear shaft 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 set- ting from the center line of the ring gear to the back
Fig.4DIFFERENTIALMOUNT
1 - DIFFERENTIAL MOUNT 2 - DIFFERENTIAL HOUSING 3 - MOUNTING BOLTS
face of the pinion is 99.690 mm (3.925 in.). The stan- dard depth provides the best teeth contact pattern.
Compensation for
is achieved with select shims. The shims are placed
pinion depth variance
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 23
Fig.6ADJUSTMENTSHIM
1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER
Depth Variance charts. Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus amount needed.
Note the painted number on the shaft of the drive pinion (–1, –2, 0, +1, +2, etc.). The numbers repre- 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 shim(s). If the num- ber is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary.
Fig.5COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PROPELLER SHAFT 3 - FLANGE YOKE 4 - REFERENCE MARK
between the rear pinion bearing cone and the pinion gear head. (Fig. 6).
If a new gear set is being installed, note the depth variance marked on 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 Pinion Gear
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
New 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 20.008FRONT AXLE - C205F
3 - 24
FRONT AXLE - C205F (Continued) PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin- ion bearings installed in housing. Take measure- ments with a Pinion Gauge Set, Pinion Block 8177, Arbor Discs 8541 and Dial Indicator C-3339 (Fig. 7).DR
Fig.8PINIONHEIGHTBLOCK
1 - PINION BLOCK 2 - PINION HEIGHT BLOCK
Fig.9PINIONGAUGETOOLS
1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK
with the scooter block against the pinion height block (Fig. 10). Slide 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 gear using the opposite sign on the variance number. For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.
Fig.7PINIONGEARDEPTHGAUGE
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 8177 and rear pinion bearing onto Screw 6741
(Fig. 7).(2) Insert assembled height gauge components, rear bearing and screw into the housing through the pinion bearing cups (Fig. 8).
(3) Install front pinion bearing and Cone 6740 onto
the screw hand tight (Fig. 7).
(4) Place Arbor Discs 8541 on Arbor D-115-3 in position in the housing side bearing cradles (Fig. 9). Install differential bearing caps on arbor discs and tighten cap bolts to specification.
(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 the housing so dial probe and scooter block are flush against the surface of the pinion height block. Hold scooter block in place and zero the dial indica- tor. Tighten dial indicator face lock screw.
(7) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 25
Fig.11ADJUSTMENTSHIM
1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER
(2) Install ring gear if necessary, on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings 8398 on differential
case.
(4) Install differential case in the housing. (5) Insert Dummy Shims 8107 3.0 mm (0.118 in.) starting point shims between both dummy bearings and the housing (Fig. 12).
Fig.10PINIONGEARDEPTHMEASUREMENT
1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
Differential side bearing preload and gear backlash is achieved by selective shims inserted between the bearing cup and the housing. The proper shim thick- ness can be determined using slip-fit Dummy Bear- ings 8398 in place of the differential side bearings and a Dial Indicator C-3339. Before proceeding with the differential bearing preload and gear backlash measurements, measure the pinion gear depth and prepare the pinion for installation. Establishing proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion is installed, and the gear backlash shim thickness is measured. The over- all shim thickness is the total of the dial indicator reading, starting point shim thicknesses, and the preload specification added together. The gear back- lash measurement determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion side of the differential (Fig. 11).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary.
(1) Remove side bearings from differential case.
Fig.12DUMMYSHIM
1 - DUMMY SHIM 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE 4 - DUMMY BEARINGS
FRONT AXLE - C205F
3 - 26
FRONT AXLE - C205F (Continued)DR
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow hammer to seat the differ- ential dummy bearings to each side of the differential housing (Fig. 13) and (Fig. 14).
Fig.14SEATRINGGEARSIDE
1 - HOUSING 2 - DEAD-BLOW HAMMER 3 - RING GEAR SIDE
Fig.13SEATPINIONGEARSIDE
1 - DEAD-BLOW HAMMER 2 - HOUSING 3 - PINION GEAR SIDE
(8) Install Pilot Stud C-3288-B in cover bolt hole
below ring gear.
(9) Attach Dial Indicator C-3339 to post and posi- tion dial indicator plunger on a flat surface on a ring gear bolt head (Fig. 15).
(10) Push and hold differential to the pinion gear side of the housing (Fig. 16) and zero dial indicator. (11) Push and hold differential case to the ring gear side and record dial indicator reading (Fig. 17). (12) Add the dial indicator reading to the starting point shim thicknesses to determine the total shim thickness necessary to achieve zero differential end play.
(13) Add 0.2 mm (0.008 in) to the zero end play total. This new total represents the shims needed to preload the new differential case bearings.
(14) Rotate dial indicator out of the way on pilot
stud.
(15) Remove differential case, dummy bearings
and dummy shims from the housing.
(16) Install the pinion gear in the housing. Install the companion flange and establish the correct pinion rotating torque.
Fig.15DIFFERENTIALSIDEPLAY
1 - DIFFERENTIAL 2 - PILOT STUD 3 - DIAL INDICATOR 4 - HOUSING
(17) Install differential case and Dummy Bearings in the housing with a single dummy shim on the ring gear side of the axle and tighten retaining cap bolts.
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 27
(20) Zero dial indicator face to pointer. (21) Push and hold differential case to ring gear
side of the housing.
(22) Record dial indicator reading. (23) Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. Add the resulting measure- ment to the thickness of the single dummy shim. This is the thickness of shim required to achieve proper backlash.
(24) Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.
(25) Rotate dial indicator out of the way on pilot
stud.
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates 8142-A on the housing and spread open enough to receive differential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing. (31) Rotate the differential case several times to
seat the side bearings.
ring gear tooth (Fig. 18).
(32) Position the dial indicator plunger against a
Fig.18RINGGEARBACKLASH
1 - RING GEAR 2 - DIAL INDICATOR
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
Fig.16ZERODIALINDICATOR
1 - PINION GEAR SIDE 2 - PILOT STUD 3 - DIAL INDICATOR
Fig.17RECORDDIALINDICATOR
1 - DIAL INDICATOR 2 - HOUSING 3 - RING GEAR SIDE
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 15).
(19) Push and hold differential case toward pinion.
FRONT AXLE - C205F
3 - 28
FRONT AXLE - C205F (Continued)(34) Zero dial indicator face to pointer. (35) Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12 mm (0.005 in.) and 0.20 mm (0.008 in.). If backlash is not within specifi- cations transfer the necessary amount of shim thick- ness from one side of the differential housing to the other (Fig. 19).
(36) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern procedure.
DR
† Gear contact pattern correct (Fig. 20). Backlash
and pinion depth is correct.
Fig.20CORRECTCONTACTPATTERN
† Ring gear too far away from pinion gear (Fig. 21). Decrease backlash by moving the ring closer to the pinion gear.
Fig.19BACKLASHSHIMADJUSTMENT
GEAR CONTACT PATTERN
Fig.21INCORRECTBACKLASH
1 - COAST SIDE TOE 2 - DRIVE SIDE HEEL
† Ring gear too close to pinion gear (Fig. 22). Increase backlash, by moving the ring away from the pinion gear.
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 the 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:
Fig.22INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL
DR FRONT AXLE - C205F (Continued) † Ring gear too far away from pinion gear (Fig. 23). Decrease backlash, by moving the ring closer to the pinion gear.
FRONT AXLE - C205F
3 - 29
† Pinion gear set too low (Fig. 25). Increase pinion gear height, by increasing the pinion depth shim thickness.
Fig.23INCORRECTBACKLASH
1 - DRIVE SIDE HEEL 2 - COAST SIDE HEEL
† Ring gear too close to pinion gear (Fig. 24). Increase backlash, by moving the ring away from the pinion gear.
Fig.25LOWPINIONHEIGHT
† Pinion gear set too high (Fig. 26). Decrease pin- ion depth, by decreasing the pinion depth shim thick- ness.
Fig.24INCORRECTBACKLASH
Fig.26HIGHPINIONHEIGHT
1 - DRIVE SIDE TOE 2 - COAST SIDE TOE
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION
Axle Ratio
Differential Case Flange Runout Differential Side Gear Clearance
Ring Gear Diameter Ring Gear Backlash Ring Gear Runout
Pinion Bearing Preload - New Bearings
Pinion Bearing Preload - Original Bearings
SPECIFICATION
3.55, 3.92
0.076 mm (0.003 in.)
0-0.15 mm (0-0.006 in.)
205 mm (8.0 in.)
0.12-0.20 mm (0.005-0.008 in.)
0.12 mm (0.005 in.)
2.0-2.8 N·m (18-25 in. lbs.)
1-2 N·m (10-20 in. lbs.)
FRONT AXLE - C205F
3 - 30
FRONT AXLE - C205F (Continued)TORQUE SPECIFICATIONS
DR
Ft. Lbs.
In. Lbs.
N·m 95
34
22
61
10870
25
15
45
80271-475
200-350
