Differential

12.ADJUSTMENTS

a.ADJUSTING THE SPLINE SHAFT BEARING PRE-LOAD

1.Using a standard spacer measuring 0.2" on the machined flat surfaces, assemble the spline shaft into transmission case with low gear, bush, collar and sleeve, medium gear assembly, high gear and high gear bush.

2.Install tail bearing using either hydraulic press or by induction heating.

3.Install gear 4WD input and secure assembly with two lock nut and lock washers.

NOTE:If the differential is in position, sufficient shim thickness must be installed to ensure that the end float of the spline shaft is not restricted by the bevel gear. If the differential is not in position, no shim should be used.

4.Install a dial indicator on the transmissions case with the stylus bearing against the machined face of the pinion.

5.Determine the end float of the spline shaft by pushing the spline shaft firmly to the rear and noting the reading, then pulling the shaft forward and noting the reading.

NOTE (1) : Several measurements should be taken, rotating the shaft at each reading.

(2) : Ensure that the extreme length of travel is reached in each direction.

6.As the pre-load on the spline shaft rear bearings is the equivalent of 0.005" tight, the thickness of spacer and shims is determined as in the following example.

End float measured..................... 0.003"

Fixed pre-load.............................. 0.005"

Therefore :-

Amount of end float to be removed is 0.007" + 0.005" = 0.008"

Standard spacer measures 0.2"

Therefore :

Thickness of spacer and shims to be installed is 0.2" - 0.008" = 0.1992".

NOTE:The average thickness of the spacer is 0.203" and graded spacers are available in thickness range of 0.192" to 0.214" in increment of 0.001".

7.Remove the lock nut and press the shaft to take out bearing and spacer out.

8.Remove the standard spacer from the shaft and install the correct thickness spacer.

9.Assemble gear 4WD, lock nut and lock washer, then secure assembly by tightening the lock nut to the specified torque.

10.Major preload of spline shaft bearing by rotating string wrapping around coupling high-low-medium using spring balance.

11.Change the graded spacer if specified preload is not achieved.

b.THE PINION CONE CENTRE DISTANCE

1.The correct cone centre distance is etched on the machined face of the pinion. Also etched on this face is the set number of the pinion and bevel gear. Ensure that the pinion and bevel gear are matched.

NOTE:Spline shaft mounting distance is directly etched on the bevel gear machined face as 0.636" or any.

2.Install the spline shaft using a shim pack of 0.090" between the bearing cone and the Transmission case.

3.Using parallel gauge block (Special Tool) measure the distance between carrier LH mounting axis on transmission case to bevel pinion machined surface.

EXAMPLE: If spline shaft mounting distance is directly etched as 0.636" and thickness of parallel gauge block is 0.628" then feeler gauge of 0.008" should go. If it is going very easily then measure the looseness, if the feeler gauge of 0.012" is going instead of 0.008", it means distance between spline shaft and transmission case is more by 0.004". Therefore 0.004" of shims must be of 0.004" is going instead of 0.008" then added. Similarly if the feeler gauge remove the shims 0.004" to increase the distance.

NOTE:Measurements should be made every 90º and the average of these readings should be taken.

4.With the correct shim pack assemble the bevel pinion with the gears and shaft. Shims to be assembled between head bearing of spline shaft and bearing mounting counter bore on transmission case.

5.Recheck the mounting distance.

During the cone center adjustment it is imperative that backlash be present.