Adjustment

For quiet and reliable final drive operation, the following five adjustments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash. Refer to Specifications.
5. Ring and pinion gear tooth contact pattern

SIDE BEARING PRELOAD
A selection of carrier side bearing adjusting washer is required for successful completion of this procedure.





1. Make sure all parts are clean and that the bearings are well lubricated with light oil or "DEXRON(tm)" type automatic transmission fluid.
2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.





3. Put the side bearing spacer in place.

CAUTION: Side bearing spacer is placed on either the right or left depending upon final drive gear ratio. Be sure to replace it on the correct side.





4. Using Tool, install original carrier side bearing preload shims on the carrier end, opposite the ring gear.
Tool number: KV38100600 (J25267)





5. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts.
Specification: 88 - 98 Nm (9 - 10 kg-m, 65 - 72 ft. lbs.)
6. Turn the carrier several times to seat the bearings.





7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129.
Specification: 34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lbs.) of pulling force at the ring gear bolt.





8. If the carrier turning torque is not within the specification range, increase or decrease the total thickness of the side bearing adjusting washers until the turning torque is correct. If the turning torque is less than the specified range, install washers of greater thickness; if the turning torque is greater than the specification, install thinner washers. For washer dimensions and part numbers, refer to Application and ID.
9. Record the total amount of washer thickness required for the correct carrier side bearing preload.





10. Remove the carrier from the final drive housing, saving the selected preload washers for later use during the assembly of the final drive unit.

PINION GEAR HEIGHT AND PINION BEARING PRELOAD





1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load shim selector Tool, J34309.





^ Front Pinion Bearing - make sure the J34309-3 front pinion bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the front pinion bearing pilot, J34309-5, to secure the bearing in its proper position.
^ Rear Pinion Bearing - the rear pinion bearing pilot, J3430915, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J34309-4, is used to lock the bearing to the assembly.





3. Place the pinion preload shim selector Tool, J34309-1, gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing.





4. Assemble the front pinion bearing inner cone and the J34309-2 gauge anvil together with the J34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J34309-16, will turn a full 360 degrees, and tighten the two sections together by hand.





5. Turn the assembly several times to seat the bearings.





6. Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765A.
Turning torque specification: 1.0 - 1.3 Nm (10 - 13 kg-cm, 8.7 - 11.3 inch lbs.)





7. Place the J34309-1 "R200A" pinion height adapter onto the gauge plate and tighten it by hand.

CAUTION: Make sure all machined surfaces are clean.

Pinion Bearing Preload Washer Selection








8. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil and seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion.








9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 inch) and your J34309-101 feeler gauge. The exact measure you get with your gauges is the thickness of the adjusting washer required. Select the correct washer.
Drive pinion bearing preload adjusting washer: Refer to Application and ID.
10. Set your selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive.

Pinion Height Adjusting Washer Selection





11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores.





12. Install the side bearing caps and tighten the cap bolts.
Specification: 88 - 98 Nm (9 - 10 kg-m, 65 - 72 ft. lbs.)





13. Select the correct standard pinion height adjusting washer thickness by using a standard gauge of 3.0 mm (0.118 inch) and your J34309-101 feeler gauge. Measure the gap between the J34309-11 "R200A" pinion height adapter and the arbor.





14. Write down your exact total measurement.





15. Correct the pinion height washer size by referring to the "pinion head number".





There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the "pinion head height number", and it refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer. Refer to Application and ID.
16. Select the correct drive pinion height washer. Drive pinion height adjusting washer: Refer to Application and ID.





17. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings.

TOOTH CONTACT
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short life, or both. With a pattern check, the most desirable contact for low noise level and long life can be assured.
1. Thoroughly clean ring gear and drive pinion teeth.





2. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.





3. Hold companion flange steady by hand and rotate the ring gear in both directions.





Tooth Contact Area