bolt pattern FORD MUSTANG 1969 Volume One Chassis

04-01-07
General Axle Service

04-01-07

Tool-4201-
C

Tool-6565 USED WITH BRACKET

FROM Too/^*207-C

FLANGE

E1743-A
procedure under Backlash and Differ-

ential Bearing Preload Adjustments.

If the tooth pattern indicates a change

in shim thickness, follow the proce-

dure under Pinion Location.

REMOVABLE CARRIER

TYPE AXLE

The shim location for the removable

carrier type axle is between the pinion

retainer and the carrier (Fig. 13).

When adjusting this type carrier re-

ducing shim thickness will move the

pinion toward the ring gear; increas-

ing shim thickness will move the pi-

nion away from the ring gear (Fig.

13).

FIG. 11—Checking Companion Flange Lateral Runout—

Thunderbird and Continental Mark III
INTEGRAL CARRIER

TYPE AXLE

8. If the runout is still excessive, re-

place the companion flange and check

the runout. If necessary, rotate the

new flange on the pinion shaft until an

acceptable runout is obtained.

If excessive runout is still evident

after replacement of the companion

flange, it will be necessary to replace

the ring and pinion gear, and repeat

the above checks until runout is within

specifications.

9. Install the driveshaft assembly

(Group 5).

PINION LOCATION

ADJUSTMENT

BACKLASH

ADJUSTMENT,

LEFT

ADJUSTING

NUT

E1476-A

FIG. 12—Pinion and Ring Gear

Tooth Contact Adjustment
—

Integral Carrier Type Axles
PINION AND RING GEAR

TOOTH CONTACT

ADJUSTMENT

Two separate adjustments affect pin-

ion and ring gear tooth contact.

They are pinion location and backlash

(Figs.
12 and 13).

Individual differences in matching

the differential housing and the gear

set require the use of shims to locate

the pinion for correct contact with the

ring gear.

When adjusting either type axle,

shim thickness should be increased or

reduced only as indicated by the tooth

pattern check described in the fore-

going Section 1.

If the tooth pattern check indicates

a change in backlash only, follow the

PINION

LOCATION

ADJUSTMENT

SHIMS

LEFT

ADJUSTING

NUT
RIGHT

ADJUSTING

BACKLASH NUT

ADJUSTMENT El 409-A

FIG. 13—Pinion and Ring Gear

Tooth Contact Adjustment—

Removable Carrier Axles
The shim location for the integral

carrier type axle, is between the pi-

nion gear and the pinion rear bearing

cone (Fig. 12). When adjusting this

type axle, increasing shim thickness

moves the pinion toward the ring

gear; reducing shim thickness moves

the pinion away from the ring gear

(Fig. 12).

BACKLASH AND DIFFERENTIAL

BEARING PRELOAD

ADJUSTMENTS (ALL AXLES)

On a Light-Duty (WER) Axle, it is

necessary to remove the rear axle

shafts prior to performing the adjust-

ment procedures. Refer to Rear Axle

Shaft Wheel Bearing and Oil Seal Re-

placement—Light-Duty (WER), Axle,

Part 4-4, Section 2.

To secure a more uniform control

of differential side bearing preload in

service repairs, a dial indicator set-up

such as shown in Fig. 12 is used.

In both types of axle (Fig. 11 and

12),
the ring gear is moved away from

or toward the pinion as described in

the following procedure.

1.
Remove the adjusting nut locks,

loosen the differential bearing cap

bolts,
then torque the bolts to 15 ft-lbs

on integral carrier type axle; 20 ft-lbs

on removable carrier type axles before

making adjustments.

2.
The left adjusting nut is on the

ring gear side of the carrier. The right

nut is on the pinion side. Loosen the

right nut until it is away from the cup.

Tighten the left nut until the ring gear

is just forced into the pinion with

0.000 backlash then rotate the pinion

several revolutions to be sure no bind-

ing is evident. (Recheck the right nutprocarmanuals.com

04-01-08
General Axle Service

04 01-08

Too/-T57L-4067-A

E 1595-A

FIG.
14
—Adjusting Side Bearing Preload—Typical

at this time to be sure that it is still

loose.) Tightening the left nut moves

the ring gear into the pinion to de-

crease backlash, and tightening the

right nut moves the ring gear away.

3.
Install a dial indicator as shown

in Fig. 14.

4.
Tighten the right nut until it first

contacts the bearing cup. Then pre-

load the bearings from 0.008-0.012

inch case spread. Rotate the pinion

gear several revolutions in each direc-

tion while the bearings are loaded, to

seat the bearings in their cups to be

sure no bind is evident. This step is

important.

5. Again loosen the right nut to re-

lease the pre-load. If there is any

backlash between the gears as shown

by the dial indicator,(Fig.l2 or Fig. 10

Part 4-4) tighten the left nut just en-

ough to remove this backlash. At this

time,
make sure that one of the slots

in the left nut is so located that the

lock can be installed without turning

the nut. Carefully, tighten the right

nut until it just contacts the cup.

6. Torque the differential cap bolts

to specification.

On integral carrier type axles, set a

preload of 0.008 to 0.012 inch case

spread for new bearings and 0.003 to

0.005 for the original bearings.

On removable carrier type axles,

the preload is 0.008 to 0.012 inch case

spread for new bearings and 0.005 to

0.008 for the original bearings. As

preload is applied from the right side,

the ring gear is forced away from the

pinion and usually results in the cor-

rect backlash.

7.
Measure the backlash on several

teeth around the ring gear. If the

measurements vary more than 0.003

inch (both integral and removable car-

rier) there is excessive runout in the
gears or their mountings, which must

be corrected to obtain a satisfactory

unit. If the backlash is out of specifi-

cation, loosen one adjusting nut and

tighten the oposite nut an equal a-

mount to move the ring gear away

from or toward the pinion. When

moving the adjusting nuts, the final

movement should always be made in a

tightening direction. For example, if

the left nut had to be loosened one

notch, loosen the nut two notches,

then tighten it one. This insures that

the nut is contacting the bearing cup,

and that the cup cannot shift after

being put in service. After all such ad-

justments, check to be sure that the

case spread remains as specified for

the new or original bearings used.

8. Again check the tooth contact

pattern. If the pattern is still incor-

rect, a change in pinion location (shim

thickness) is indicated.

PINION LOCATION

Removable Carrier Type Axle

1.
Remove the attaching bolts and

the pinion and bearing retainer assem-

bly from the carrier.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in Section 1.

3.
Replace the pinion retainer O-

ring (Fig. 39, Part 4-2). Coat the O-

ring with axle lubricant before install-

ing. Do not roll the O-ring into the

groove. Snap it into position.

4.
Being careful not to pinch the

O-ring, install the pinion and bearing

retainer assembly in the carrier with

the corrected shim pack.

Before installing the pinion and

bearing retainer assembly, determine

which type of gear set is being used.
The non-hunting and pantial non-

hunting types can be identified by the

paint timing marks on the gear teeth

(Fig. 51, Part 4-2). Part 4-5 can also

be referred to for identification.

If the gear set is of the non-hunting

or partial non-hunting type clean the

teeth on both the pinion and drive

gear so that the timing marks are vis-

ible.
Rotate the differential case and

ring gear assembly in the carrier until

the marked teeth on the ring gear are

opposite the pinion entry hole. Place

the assembly in the carrier so that the

marked tooth on the pinion indexes

between the marked teeth on the ring

gear (Fig. 51, Part 4-2).

In almost every case of improper

assembly (gear assembled out of time)

the noise level and probability of fai-

lure will be higher than they would be

with properly assembled gears.

When installing the hunting type

gear set (no timing marks), assemble

the pinion and retainer assembly into

the carrier without regard to the

matching on any particular gear teeth.

5.
Install the retainer-to-carrier

mounting bolts and torque to specifi-

cations.

6. Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedures.

7.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.

Integral Carrier Type Axle

1.
Remove the differential case and

the drive pinion from the carrier cast-

ing, and then remove the pinion bear-

ings as described under Removal of

Differential Case and Drive Pinion in

Section 4.

2.
Measure the original shim thick-

ness with a micrometer. Increase or

decrease the shim thickness as indicat-

ed by the tooth pattern check des-

cribed in the foregoing Section 1 and

shown in Fig. 4.

3.
Install the corrected shim pack

and the bearings on the pinion, and

then install the pinion and the differ-

ential case in the carrier casting as

outlined under Installation of Drive

Pinion and Differential Case in Sec-

tion 4 of Part 4-3.

4.
Adjust the backlash between the

ring gear and pinion as outlined in the

foregoing procedure.

5.
Make a tooth pattern check. If

the pattern is still unsatisfactory, re-

peat this procedure changing the shim

thickness each time until a satisfactory

tooth pattern is obtained.procarmanuals.com

04-01-09
General Axle Service

04-01-09

CLEANING AND INSPECTION

INSPECTION BEFORE

DISASSEMBLY OF CARRIER

(ALL AXLES)

The differential case or carrier

should be inspected before any parts

are removed from it. These inspec-

tions can help to find the cause of the

trouble and to determine the correc-

tions needed.

Mount the carrier in the holding

fixture shown in Fig. 15. Wipe the lu-

bricant from the internal working

parts,
and visually inspect the parts

for wear or damage.

Tool-T57L-500-A

FIG. 15
— Bench
Fixture for

Carrier Overhaul—Typical

Rotate the gears to see if there is

any roughness which would indicate

damaged bearings or chipped gears.

Check the gear teeth for scoring or

signs of abnormal wear.

Set up a dial indicator (Fig. 16) and

check the backlash at several points

around the ring gear. Backlash should

be within specifications.
If no obvious defect is noted, check

the gear tooth contact.

To check the gear tooth contact,

paint the gear teeth with the special

compound furnished with each service

ring gear and pinion. A mixture that

is too wet will run and smear. Too dry

a mixture cannot be pressed out from

between the teeth.

As shown in Fig. 17, rotate the ring

gear (use a box wrench on the ring

gear attaching bolts for a lever) five

complete revolutions in both directions

or until a clear tooth contact pattern

is obtained.
DIFFERENTIAL BEARING

CAP BOLTS

E 1776-A

FIG. 76-Backlash Check-

Typical
E
1001 - C

FIG.
7
7—Checking Gear Tooth

Contact—Typical

Certain types of gear tooth contact

patterns on the ring gear indicate in-

correct adjustment. Noise caused by

incorrect adjustment can often be cor-

rected by readjusting the gears. Ac-

ceptable patterns and the necessary

corrections are explained under Tooth

Contact Pattern Check in Section I.

Gear tooth runout can sometimes

be detected by an erratic pattern on

the teeth. However, a dial indicator

should be used to measure the runout

of the back face of the ring gear as

shown in Fig. 18. If this runout ex-

ceeds specifications, disassemble the

carrier and replace necessary parts as

indicated in Part 4-2, Section 4 and

Part 4-3, Section 4.
1699-A

FIG. 18 -Checking Ring Gear

Runout—Typical

Loosen the differential bearing cap

bolts,
and then torque them to 25 ft-

lbs.
Remove the adjusting nut locks.

Carefully loosen one of the adjusting

nuts to determine if any differential

bearing preload remains. If any pre-

load remains, the differential bearings

may be re-used, provided they are not

pitted or damaged.

INSPECTION AFTER

DISASSEMBLY OF CARRIER

(ALL AXLES)

Thoroughly clean all parts. Syn-

thetic seals must not he cleaned, soak-

ed or washed in cleaning solvents.

Always use clean solvent when clean-

ing hearings. Oil the bearings im-

mediately after cleaning to prevent rust-

ing. Inspect the parts for defects.

Clean the inside of the carrier before

rebuilding it. When a scored gear set

is replaced, the axle housing should he

washed thoroughly and steam cleaned.

This can onl\ be done effectively if the

axle shafts and shaft seals are re-

moved from the housing. Inspect indi-

vidual parts as outlined below.

GEARS

Examine the pinion and ring gear

teeth for scoring or excessive wear.

Extreme care must he taken not to

damage the pilot hearing surface of

the pinion.procarmanuals.com

04-02-16

Rear Axle — Removable Carrier Type
04-02-16

Tool~T53L-200-A

Tool-T57L-4625-A

or 4625-K

E 1725-A

FIG. 29—Removing Pilot Bearing

to adjust for individual variations in

both the carrier housing dimension

and in the original gear set dimension.

Therefore, to select the correct shim

thickness for the new gear set to be

installed, follow these steps:

1.
Use a micrometer to measure

the thickness of the original shim re-

moved from the axle and use the same

thickness upon installation of the re-

placement carrier assembly or drive

pinion. If further shim change is ne-

cessary, it will be indicated in the

tooth pattern check.

2.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to

determine if further shim changes are

required. Nominal shim thicknesses is

E 1734-A
PINION BEARING

RETAINER

E 1482-B

FIG. 31—Removing Pinion Front

Bearing Cup

indicated in Part 4-3, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, appears on the bolt hole face

of the ring gear and on the head of

the drive pinion (Fig. 35).

3.
After determining the correct

shim thickness as explained in the

ss
Rom

Too/-T58L-70?-A

or4675-J

FIG. 30—Removing Pinion Front

Bearing Cup
FIG. 32—Removing Pinion Rear

Bearing Cup

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL
CASE

BEARINGS
AND
RING

GEAR
TEST

If the ring gear runout check (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the hubs.
Press Ram

Tool -

T57L - 4614-A
Tool -

T57L - 4676-A2

1736-/

FIG. 33—Installing Pinion Front

Bearing Cup

too;-
IB .

T55P-46U
A2V •H"^^

\
Press Ram

Tool-

T57L-46U-A

FIG. 34—Installing Pinion Rear

Bearing Cup

2.
Place the cups on the bearings

and set the differential case in the car-

rier.

3.
Install the bearing caps and ad-

justing nuts as outlined in Steps 11

thru 14 under Assembly and Installa-

tion of Conventional Differential Case

which follows in this section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 35— Pinion and Ring Gear

Markingsprocarmanuals.com

04-02-20
Rear Axle — Removable Carrier Type

0402-20

THRUST WASHER

E1175-B

FIG. 48—Assembling Differential Case

13.
Install the bearing cap bolts

and alternately torque them. The 9

3/8 inch ring gear size axle requires

60-70 ft-lbs. The 8 3/4 inch and 9

inch ring gear size axles require 70-85

ft-lbs.

14.
If the adjusting nuts do not turn

freely as the cap bolts are tightened,

remove the bearing caps and again in-

spect for damaged threads of incor-

rectly positioned caps. Tightening the

bolts to the specified torque is done to
be sure that the cups and adjusting

nuts are seated. Loosen the cap bolts,

and torque them to only 25 ft. lbs be-

fore making adjustments.

15.
Adjust the backlash between the

DIFFERENTIAL

BEARING

CONE AND

ROLLER

E 1700-A

FIG. 49—
Installing
Differential

Bearing
1376-A

FIG. 50—Installing Differential

bearing
ring gear and pinion as outlined in

Part 4-1, Section 2.

16.
Be sure to make a final tooth

pattern check before installing the

carrier assembly in the axle housing.

Limited-Slip

Differential Case

1.
Place the inner side gear and

thrust washer in the differential case

(Fig. 52). Lubricate all parts liberally

with limited-slip axle lubricant during

assembly.

2.
With a soft-faced hammer, drive

the pinion shaft into the case only far

enough to retain a pinion thrust wash-

er and pinion gear.

3.
Place the second pinion and

thrust washer in position and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock in holes.

4.
Install the pinion shaft lock pin.

The lock pin must not extend beyond

the surface of the case.

5. Insert two 2-inch 7/16 (NF)

bolts through the differential case

flange, and thread them three or four

turns into the ring gear as a guide in

aligning the ring gear bolt holes. Press

or tap the ring gear into position.

6. Clamp the differential case in a

soft-jawed vise. Install the differential

outer side gear on the differential pin-

ion gears. Place the clutch hub on

the side gear. Place the thrusi: washer

on the huh

Limited-Slip dutch

Plate Installation

Prior to clutch plate installation,

the friction bonded plates must be

soaked in C6AZ-19570-C (ESW-

M2C-104-A) differential lubricant for

approximately 1/2 hour. In addition,

the differential lubricant must be lib-

erally applied to all components to

be assembled.

1.
Place the clutch hub into posi-

tion in a soft-jawed vise.

2.
First, install a steel clutch plate

in the cavity of the differential case

opposite the ring gear and then a

bonded friction plate (Fig. 53). Any

tab on the steel plates can be inserted

into any cavity in the differential case,

however when the first steel plate is

inserted the others must be placed in

the same manner (Fig. 54) so the tabs

with slots line up. Install the remain-

ing plates: a steel plate, bonded fric-

tion plate, a steel plate, bonded fric-

tion plate and lastly a steel plate.

Make sure the bonded friction plate

inner-spline teeth properly engage the

hub spline.procarmanuals.com

04-03-09
Rear Axles — Integral Carrier Type

04-03-09

E1914A

FIG. 22—Pinion Bearing Cup Removal or Installation

\

MATCHED

GEAR SET

IDENTIFICATION

E 1628-A

FIG. 23—Pinion and Ring

Gear Marking

casting with a drift. Install the new

cups with the tool shown in Fig. 22.

Make sure the cups are properly seat-

ed in their bores. If a 0.0015-inch feel-

er gauge can be inserted between a

cup and the bottom of its bore at any

point around the cup the cup is not

properly seated.

Whenever the cups are replaced, the

cone and roller assemblies should also

be replaced.

DRIVE PINION AND GEAR

SET

Individual differences in machining

the carrier casting and the gear set re-

quire a shim between the pinion rear

bearing cone and the pinion gear to

locate the pinion for correct tooth

contact with the ring gear.

When replacing a ring gear and pin-

ion it should be noted that the original

factory installed shim is of the correct

thickness to adjust for individual vari-

ations in both the carrier casting di-

mension and in the original gear set

dimension; therefore, to select the cor-

rect shim thickness for the new gear
set to be installed, follow these steps:

1.
With a micrometer, measure the

thickness of the original shim removed

from the axle and use the same thick-

ness upon installation of the replace-

ment carrier assembly or drive pinion.

2.
If further shim change is neces-

sary, it will be indicated in the tooth

pattern check.

3.
If the original shim is lost, sub-

stitute a nominal shim for the original

and use the tooth pattern check to de-

termine if further shim changes are re-

quired. Nominal shim thickness is in-

dicated in Part 4-5, Specifications.

A new ring gear and pinion should

always be installed in an axle as a

matched set (never separately). Be

sure the same identifying (matching)

number, painted in white, appears on

the bolt hole face of the ring gear and

on the head of the drive pinion

(Fig. 23).

4.
After determining the correct

shim thickness as explained in the

foregoing steps, install the new pinion

and ring gear as outlined under As-

sembly.

DIFFERENTIAL CASE,

BEARINGS, AND RING

GEAR

If the ring gear runout checK (be-

fore disassembly) exceeded specifica-

tions,
the condition may be caused by

a warped gear, a defective case, or ex-

cessively worn differential bearings.

To determine the cause of excessive

runout proceed as follows:

1.
Assemble the two halves of the

differential case together without the

ring gear, and press the two differen-

tial side bearings on the case hubs.

2.
Place the cups on the bearings

and set the differential case in the car-

rier.
3.
Install the bearing caps and ad-

justing nuts as outlined in steps 11

thru 14 under Installation of Drive

Pinion and Differential Case in this

section.

4.
Tighten the right nut two notches

beyond the position where it first con-

tacts the bearing cup. Rotate the dif-

ferential case several revolutions in

each direction while the bearings are

loaded to seat the bearings in their

cups.
This step is important.,

5.
Again loosen the right nut to re-

lease the preload. Check to see that

the left nut contacts the bearing cup.

Using the dial indicator set-up shown

in Fig. 10, Part 4-1, adjust the preload

to 0.008 to 0.012 case spread for new

bearings or 0.005 to 0.008 for the

original bearings, if reused.

6. Check the runout of the differen-

tial case flange with a dial indicator.

If the runout does not now exceed

specifications, install a new ring gear.

If the runout still exceeds specifica-

tions,
the ring gear is true and the

trouble is due to either a defective

case or worn bearings.

7.
Remove the differential case

from the carrier and remove the side

bearings from the case.

8. Install new bearings on the case

hubs,
and again install the differential

assembly in the carrier without the

ring gear.

9. Check the case runout again with

the new bearings. If the runout is now

within limits, the old bearings were

excessively worn. Use the new bear-

ings for assembly. If the runout is still

excessive, the case is defective and

should be replaced.

ASSEMBLY

Refer to Part 4-1 for Cleaning and

Inspection before starting assembly

operations.

ASSEMBLY OF

DIFFERENTIAL CASE

1.
Lubricate all the differential

parts with axle lubricant, before they

are installed in the case.

2.
Place the side gears and thrust

washers in the case.

3.
Place the two pinion gears and

thrust washers exactly opposite each

other in the case openings and in

mesh with the side gears.

4.
Turn the pinions and thrust

washers until the holes in the pinion

gears align with the pinion shaft holes

in the case.

5.
Start the pinion shaft into the

differential case. Carefully align the

shaft lock pin hole with the pin holeprocarmanuals.com

04-04-08
Rear Axle — Ford Light-Duty (WER)

04-04-08

E 1577-A

75—Pinion Bearing
Cup
Installation—Typical

2.
Remove
the
bolts that attach
the

ring gear
to the
differential case. Press

the ring gear from
the
case
or tap it

off with
a
soft-faced hammer.

PARTS REPAIR
OR

REPLACEMENT

Clean
and
inspect
all the
parts
as

outlined
in
Cleaning
and
Inspection,

Part 4-1, Section
3 of
this Shop
Man-

ual.
Before assembling
the
carrier,
re-

pair
or
replace
all
parts
as
indicated

by
the
inspection.
The
principle
re-

placement operations
are
covered
in

the following procedures.
All
other
re-

pair
or
replacement operations
are

performed during
the
Cleaning
and

Inspection, Part 4-1, Section
3
opera-

tions noted above,
or
during
the as-

sembly
in
this section.

PINION BEARING CUPS

Do
not
remove
the
pinion bearing

cups from
the
carrier casting unless

the cups
are
worn
or
damaged.

If
the
pinion bearing cups
are to be

replaced, drive them
out of the
carrier

casting with
a
drift.
Tap on the
side

opposite
the cup. Use
care
to
prevent

the cups from cocking
in the
carrier.

Install
the new
cups with
the
tool

shown
in Fig. 15.
Make sure
the
cups

are properly seated
in
their bores.
If a

0.0015-inch feeler gauge
can be
insert-

ed between
a cup and the
bottom
of

its bore
at any
point around
the cup,

the
cup is not
properly seated.

Whenever
the
cups
are
replaced,
the

cone
and
roller assemblies should also

be replaced.
DRIVE PINION
AND

GEAR
SET

Individual differences
in
machining

the carrier casting
and the
gear
set re-

quire
a
shim between
the
pinion rear

bearing cone
and the
pinion gear
to

locate
the
pinion
for
correct tooth

contact with
the
ring gear.

When replacing
a
ring gear
and pin-

ion
it
should
be
noted that
the
original

factory installed shim
is of the
correct

thickness
to
adjust
for
individual vari-

ations
in
both
the
carrier casting
di-

mension
and in the
original gear
set

dimension; therefore,
to
select
the cor-

rect shim thickness
for the new
gear

set
to be
installed, follow these steps:

1.
Use a
micrometer
to
measure

the thickness
of the
original shim
re-

moved from
the
axle
and use the
same

thickness upon installation
of the re-

placement carrier assembly
or
drive

pinion.
If
further shim change
is nec-

essary,
it
will
be
indicated
in the
tooth

pattern check.

2.
If the
original shim
is
lost,
sub-

stitute
a
nominal shim
for the
original

and
use the
tooth pattern check
to de-

termine
if
further shim changes
are re-

quired. Nominal shim thicknesses
is

indicated
in
Part
4-3,
Specifications.

A
new
ring gear
and
pinion should

always
be
installed
in an
axle
as a

matched
set
(never separately).
Be

sure
the
same identifying (matching)

number, painted, appears
on the
bolt

hole face
of the
ring gear
and on the

head
of the
drive pinion
(Fig. 16).

3.
After determining
the
correct

shim thickness
as
explained
in the

foregoing steps, install
the new
pinion

and ring gear
as
outlined under
As-

sembly which follows
in
this section.
MATCHED

GEAR
SET

IDENTIFICATION

E 1628-A

. ?6—Pinion
and
Ring Gear

Markings

3ress
Ro-

Tool

T57L-4221-A-1

DIFFERENTIAL

BEARING CONE

ANC ROLLER

|E 1579-A

PIG. 77—Differential Bearing

Installation

DIFFERENTIAL CASE,

BEARINGS,
AND
DRIVEN

GEAR

If
the
ring gear runout check
(be-

fore disassembly) exceeded specifica-

tions,
the
condition
may be
caused
by

a warped gear,
a
defective case,
or ex-

cessively worn differential bearings.

To determine
the
cause
of
excessive

runout, proceed
as
follows:

1.
Press
the
original bearings
on

the one-piece differential case hubs

without
the
ring gear installed.

2.
Place
the
differential bearing

cups
on the
bearing cone
and
roller

and
set the
differential case
in the car-

rier.

3.
Install
the
matched (marked)

bearing caps
and
adjusting nuts
as

outlined
in
steps
11
thru
14
under
In-

stallation
of
Drive Pinion
and
Differ-

ential Case which follows
in
this
sec-

tion.

4.
Tighten
the
left adjuster
nut
until

it just touches
the
bearing
cup
then

tighten
the nut two
notches beyond

the point where
it
first contacts
the

bearing
cup.
Rotate
the
differentialprocarmanuals.com