Differential Backlash and Bearings - Adjust (SENR1347)

SMCS - 3258
i02254116

Illustration 1 g00405449
Differential and Bevel Gear

(1) Adjusting nut lock

(2) Bolts

(3) Adjusting nut

(4) Bolts

(5) Cover

(6) Shims

(7) Pin
(8) Bearing cup

(9) Bearing cone

(10) Shims

(11) Bevel gear

(12) Housing

(13) Bearing cup

(14) Bearing cone

(15) Retainer

(16) Bolts

(17) Adjusting nut lock

(18) Adjusting nut

(19) Differential case

(20) Bolts

(21) Differential

(22) Bearing cone

(23) Bearing cup

(24) Carrier assembly

(25) Bearing cup

(26) Bearing cone

(27) Washer

(28) Nut

(29) Bevel pinion

Note: The following procedure controls bearing preload. The procedure provides the
same results for new bearings and for used bearings.

1. Install bevel gear (11) onto differential case (19) . Torque for the 36 bolts is
750 ± 90 N·m (550 ± 65 lb ft).
2. Install bearing cone (9) and bearing cone (22) onto differential group (21) .
Make sure that the bearing cone is fully seated. Lubricate the bearing cone
with SAE 50W differential oil.

3. Press bearing cup (13) and bearing cup (25) on pinion housing (12) . Make
sure that the bearing cups are fully seated.

4. Press bearing cone (14) on pinion (29) . Make sure that the bearing cone is
fully seated. Lubricate the bearing cone with SAE 50W differential oil.

5. Install pinion (29) in housing (12) . Press bearing cone (26) onto the pinion
shaft. Allow a small amount of end play to remain. Lubricate the bearing cone
with SAE 50W differential oil.

Note: If you freeze the bearing cups, allow the parts to reach a uniform
temperature. Then use a driver or a press to reset the bearing cups. The limit
for freezing the bearing cups is -29°C (-20°F). Remove any frost and wipe the
bearing cups dry. Lubricate the bearing cups with SAE 50W differential oil in
order to prevent rust on the bearing cups.

Note: If you heat the bearing cones, allow the parts to reach a uniform
temperature. Then use a driver or a press to reset the bearing cones. The limit
for heating the bearing cones is a maximum of 135°C (275°F) for a maximum
of four hours. Lubricate the bearing cones with SAE 50W differential oil after
the bearing cones have cooled in order to prevent rust on the bearing cones.

6. Secure the assembled pinion housing (12) in a holding fixture. Install washer
(27) and nut (28) .

Table 1
Required Tools
Part Number Description Quantity
1U-6691 Socket Wrench Assembly 1

7. While you rotate pinion shaft (29) , tighten nut (28) in order to achieve a
preload rolling torque of 2.2 to 5.1 N·m (20 to 45 lb in). This is the torque that
is needed in order to rotate pinion (29) . Make sure that there is zero end play
of pinion shaft (29) .

Note: Reduce preload rolling torque to 1.1 to 2.55 N·m (10 to 23 lb in) for used
roller bearings with more than 100 hours of operation.

8. If the preload rolling torque for the pinion exceeds the specifications, back off
nut (28) by 1/8 turn and reseat bearing cone (26) and washer (27) against nut
(28) . Perform Step 7 again.
 Illustration 2 g00103469
Stake Nut and Tooling

9. When the torque for rotating pinion (29) is correct, stake nut (28) by peening
the collar into the slot in the pinion shaft. Proper peening requires the use of a
punch with a spherical nose. The punch should have a nose that is (C)
diameter. The punch should be held at an angle (B) . The desired result is a
stake of minimum length (D) and minimum depth (E) . See Illustration 2 for a
view of a completed staked nut.

List of dimensions for a staked nut

Dimension (B) ... 10 to 30°

Dimension (C) ... 7.5 to 8.0 mm (0.30 to 0.32 inch)
Dimension (D) ... 4.7 mm (0.19 inch)
Dimension (E) ... 2.5 mm (0.10 inch)
Note: The nut may be reused if the collar is not cracked during removal or
during restaking.

10. Secure carrier assembly (24) in a holding fixture.

11. Install the pinion subassembly in carrier assembly (24) with 80 percent of a
new shim pack (10) . Make sure that the axle centerline is vertical and that the
teeth of bevel gear (11) are facing upward, as shown.
 12. Tighten bolts (2) and (16) in each bearing cap to a torque of 25 N·m (18 lb ft).

13. Move adjusting nut (3) and adjusting nut (18) to a position that maintains the
gear backlash and a slight bearing end play, but not a tight gear mesh.

14. Reposition the differential assembly so that the pinion shaft is vertical and the
gear end is downward.

15. Measure the torque for rotating pinion (29) and record the measured torque.

16. Move adjusting nut (3) to the zero backlash position. Back off adjusting nut (3)
by one-half turn.

17. Move adjusting nut (18) while you rotate bevel gear (11) . Monitor the torque
that is required to rotate pinion (29) .

18. Continue to move adjusting nut (18) until a torque is registered over the torque
that was measured in Step 15. This is the seated position.

19. Move adjusting nut (18) while rotating the bevel gear set until the overall rolling
torque is 4 N·m to 15 N·m (35 lb in to 130 lb in).

20. Measure the backlash between bevel gear (11) and pinion gear (29) . Measure
the backlash at three equally spaced positions around the bevel gear. The
backlash must be 0.40 ± 0.12 mm (0.016 ± 0.005 inch).

21. If the backlash does not meet the specification at any one of the three
positions, back off one adjusting nut and move the other adjusting nut forward
by the same amount. This will maintain the bearing preload.

22. Measure the torque for rotating pinion (29) . The torque must be 4 N·m to 15
N·m (35 lb in to 130 lb in).

23. When proper backlash has been obtained tighten bolts (2) and (16) in each
bearing cap to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

24. Install adjusting nut locks (1) and (17) .

Tooth Contact Pattern Adjustment (Pinion and Bevel

Gear)
 Illustration 3 g00103470

1. After the backlash adjustment and the preload adjustment have been made,
check the tooth contact between pinion (29) and bevel gear (11) by using the
following procedure:
a. Put a small amount of Prussian blue, of red lead, or of paint on the
teeth of bevel gear (11) .

b. Turn pinion (29) in both directions.

c. The end of the correct area of tooth contact is near the inside end of the
teeth of the bevel gear (11) . The contact area should extend halfway
across the length of the teeth. See Illustration 3 for the correct area of
tooth contact.
 Illustration 4 g00103471

2. If the area of tooth contact looks like Illustration 4, use the following procedure:
a. Remove some of the shims (10) .

b. Perform Step 14 through Step 24 again.

c. Perform Step 2 and Step 3 again in order to check the area of tooth
contact.

Illustration 5 g00103472

3. If the area of tooth contact looks like Illustration 5, use the following procedure:
a. Add some of the shims (10) .

b. Perform Step 14 through Step 24 again.

c. Perform Step 2 and Step 3 again in order to check the area of tooth
contact.

Note: Always make sure that the backlash adjustment is correct before
an adjustment is made to the area of tooth contact. Several
adjustments to the backlash and to the tooth contact may be necessary
in order to achieve the correct adjustments.

4. Install pin (7) and cover (5) without shims (6) . Tighten bolts (4) enough in
order to remove any clearance between the pin and the cover.

5. Measure the distance between the face of the cover (5) and the face of the
axle housing. Install the shims (6) so that the pin is under a preload of -0.03
mm (-.001 inch) or an end play of 0.03 mm (.001 inch).
 6. Install retainer (15) .

1JW1-UP, 2211-UP, 2KZ1-UP, 4FR1-UP, 7HK1-UP, 7HR1-UP, A4W1-UP, ADZ1-

UP, AMP1-UP, AZX1-UP, BBN1-UP, BCR1-UP, BTW1-UP, BWX1-UP, H4C1-UP

PSP-00052014
2021/10/04
10:44:33+02:00
i00831199
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