Differential and Driveline96zjs_3

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DIFFERENTIAL AND DRIVELINE

MODEL 44 AXLE

CONTENTSpage page

GENERAL INFORMATIONLUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . 1MODEL 44 ALUMINUM AXLE . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATIONSTANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 2TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . . 3

DIAGNOSIS AND TESTINGBEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 3DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 4GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . . 3TRAC–LOK DIFFERENTIAL NOISE . . . . . . . . . . . 4TRAC–LOK TEST . . . . . . . . . . . . . . . . . . . . . . . . 7VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE PROCEDURESLUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 7

REMOVAL AND INSTALLATIONAXLE SHAFT SEAL AND BEARING . . . . . . . . . . 13AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12COLLAPSIBLE SPACER . . . . . . . . . . . . . . . . . . 10DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 15DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 13

FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 20PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 16PINION SHAFT SEAL REPLACEMENT . . . . . . . . 8REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DISASSEMBLY AND ASSEMBLYSTANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 20TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 21

CLEANING AND INSPECTIONAXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . 25TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ADJUSTMENTSDIFFERENTIAL BEARING PRELOAD AND

GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 27GEAR CONTACT PATTERN ANALYSIS . . . . . . . 29PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . 25

SPECIFICATIONSMODEL 44 AXLE . . . . . . . . . . . . . . . . . . . . . . . 31TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SPECIAL TOOLSMODEL 44 AXLE . . . . . . . . . . . . . . . . . . . . . . . 31

GENERAL INFORMATION

MODEL 44 ALUMINUM AXLEThe Model 44 hous ing has an a luminum cen ter

casting (differential housing) with axle shaft tubesextending from either s ide . The tubes are pressedinto the differential housing to form a one–piece axle

housing.The integral type housing, hypoid gear design hasthe center l ine of the pinion set below t he center l ineof the ring gear.

The axle has a vent hose to re l ieve in ternal pres-sure caused by lubr icant vapor iza t ion and in ternalexpansion.

The axles are equipped with semi–float ing axleshafts, meaning that loads are supported by the axleshaf t and bear ings . The axle shaf ts are re ta ined byC–clips in the differential side gears.

The cover provides a means for servicing the differ-ent ia l without removing the axle . Model 44 axleshave the assembly par t number an d gear ra t io li stedon a t ag a t t ached to the d iffe ren t ia l hous ing by ahousing cover bolt. Build da te identificat ion codes ar es tamped on an axle shaf t tube .

The differential case is a one–piece design. The dif-fer en t ia l p in ion m a te s ha ft is r et a in ed wit h athreaded pin . Different ia l bear ing pre load and r ingge ar b ack la s h is a d ju s ted b y s h im s p os it ion edbetween the s ide bear ing race and the housing. P in-ion gea r dep th is ad jus t ed by sh ims pos it ionedbetween the pinion gear and the inner bearing cone.Pinion gear bearing preload is set and maintained bythe use of a collapsible spacer (Fig. 1).

LUBRICANT SPECIFICATIONSA multi–purpose, hypoid gear lubricant which con-

forms to the following specifications should be used.

ZJ DIFFERENTIAL AND DRIVELINE 3 - 1



Mopar Hypoid Gear Lubr icant conforms to a l l of these specifications.

• The lubr icant should have MIL–L–2105C andAPI GL 5 quality specifications.

• Lubricant i s a thermal ly s table SAE 80W–90gear lubricant.

• Lubricant for axles intended for heavy-duty ortrailer t ow u se is SAE 75W–140 SYNTHETIC gearlubricant.

Tra c-lok differentials require th e a ddition of 4 oz.of friction modifier to the axle lubricant . The Dana44 rear axle lubricant capacity is 2.25 L (4.75 pts.)total, including the friction modifier if necessary.

CAUTION: If axle is submerged in water, lubricantmust be replaced immediately to avoid possiblepremature axle failure.

DESCRIPTION AND OPERATION

STANDARD DIFFERENTIALThe different ia l gear sys tem divides the torque

between the axle shaf ts . I t a l lows the axle shaf ts torotate at different speeds when turning corners.

Each different ia l s ide gear i s splined to a n axlesha ft . The p in ion gea r s a re moun ted on a p in ionmate sha f t and a re f r ee to ro t a t e on the sha f t . Thepinion gear is f i t ted in a bore in the differential caseand is posit ioned at a right angle to the axle shafts.

In operation, power flow occurs as follows:• The pinion gear rotates the ring gear• The r ing gear (bol ted to the d ifferent ia l case)

rotates the case• The different ia l p in ion gears (mounted on the

pinion mate shaft in the case) rotate the side gears• The side gears (splined to the axle shafts) rotate

the shaf ts

During straight-ahead driving, the differential pin-ion gears do not rotate on th e pinion mate shaft . Thisoccurs because input torque applied to the gears i sdivided and distributed equally between the two sidegears. As a result , the pinion gears revolve with thepinion mate shaft but do not rotate a round it (Fig. 2).

When tu rn ing corne r s, t he ou t s ide whee l mus tt r ave l a grea t er d is t ance than the in s ide whee l i norder to comple te a tu rn . The d iffe rence mus t becompensated for in order to prevent the t i res fromscuffing and skidding through turn s. To accomplishthis, the differential allows the axle shafts to turn atunequal speeds (Fig. 3). In th is instance, the inputtorque appli ed to the p in ion gea r s is not d ividedequally. The pinion gears now rotate around the pin-ion mate shaft in opposite directions. This allows thes id e ge ar a n d a xle s h aft a t t a ch ed t o t h e ou t sid ewheel to ro ta te a t a fas ter speed.

Fig. 1 Axle Adjustment Shims and Spacer

Fig. 2 Differential Operation—Straight Ahead Driving

Fig. 3 Differential Operation—On Turns

3 - 2 DIFFERENTIAL AND DRIVELINE ZJ

GENERAL I NFORMATION (Continued)



TRAC-LOK OPERATIONIn a conventional differential , if one wheel spins,

the opposite wheel will generate only as much torqueas the spinning wheel.

In the Trac-lok different ia l, par t of the r ing geartorque is t ransmitted through clutch packs which con-

tain multiple discs. The clutches will have r adial grooveson the pla tes , a nd concentr ic grooves on the discs orbonded fiber material that is smooth in appearance.

In operation, the Trac-lok clutches are engaged bytwo concurrent forces. The fi rst being the pre loadforce exe r t ed th rough Belleville spr ing washe r swithin the clutch packs. The second is the separatingfor ces gen er a t ed b y t h e s id e ge ar s a s t or qu e isapplied through the ring gear (Fig. 4).

The Trac-lok design provides the differential actionneeded for turning corners and for dr iv ing s t ra ightahead during periods of unequal traction. When onewheel looses t raction, the clutch packs tran sfer addi-t ional torque to th e wheel having the most t rac t ion.Trac-lok different ia ls res is t wheel spin on bumpyroads and p rovide more pu ll ing power when onewheel looses traction. Pulling power is provided con-t inuously unt i l both wheels loose t rac t ion. I f bothwheels sl ip due to unequal traction, Trac-lok opera-t ion is normal . In ext reme cases of d ifferences of traction, the wheel with the least traction may spin.

DIAGNOSIS AND TESTING

GEAR NOISEAxle gear noise can be caused by insufficient lubri-

cant, incorrect backlash, tooth contact, or worn/dam-aged gears.

Gear noise usua lly happens a t a speci fic speedrange. The range is 30 to 40 mph, or above 50 mph.The noise can a lso occur dur ing a speci fic type of driving condition. These conditions ar e accelera tion,deceleration, coast, or constant load.

When road tes t ing, a ccelera te the vehicle t o t hespeed ra nge where the noise i s the greates t . Shiftout–of–gear and coast through the peak–noise range.If the noise stops or changes greatly:

• Check for insufficient lubrican t.• Incorrect r ing gear backlash.• Gear damage.Differential side and pinion gears can be checked

by tu rning th e vehicle. They usual ly do not causenoise in s t ra ight–ahead dr iv ing. The s ide gears areloaded during vehicle turns. If noise does occur dur-ing vehicle tur ns, t he side or pinion gears could beworn or damaged. A worn pinion gear mate shaft canalso cause a snapping or a knocking noise.

BEARING NOISEThe axle shaft , differential an d pinion gear bear-

ings can a l l produce noise when worn or damaged.Bearing noise can be either a whining, or a growlingsound.

Pinion gear bear ings have a constant–pi tch noise .This noise changes only with vehicle speed. Pinionbear ing no ise wil l be h igher because i t rot a t e s a t afaster rate. Drive the vehicle and load the differential .I f bear ing noise occurs , the rear p inion bear ing is thesource of the noise . I f the bear ing noise is heard dur-ing a coast, the front pinion bearing is the source.

Worn or damaged differential bearings usually pro-duce a low pitch noise. Differential bearing n oise issimilar to pinion bearing noise. The pitch of differen-t ia l bear ing noise i s a lso constant and var ies onlywith vehicle speed.

Axle shaft bear ings produce noise and vibra t ionwhen worn or damaged. The noise generally changeswhen the bearings are loaded. Road test the vehicle.Turn the vehicle sharply to the left and to the r ight .Th is will l oad the bea r ings and change the noiselevel. Where axle bearing dama ge is sl ight, t he noiseis usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCKLow speed knock is genera lly caused by a worn

U–joint or by worn side–gear thru st washers. A wornp in ion gea r sha ft bore will a lso cause low speedknock.

Fig. 4 Trac-lok Limited Slip Differential Operation


DESCRIPTION AND OPERATION (Continued)



VIBRATIONVibra t ion a t t he r ea r of t he veh icle is u sua lly

caused by a:• 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).Check for loose or dam aged front–end components

or engine/t ransmission mounts . These componentsca n con t r ib ut e t o w ha t a p pe ar s t o b e a r ea r –e ndvibrat ion. Do not overlook en gine accessories, br ack-ets and drive belts.

All d r ive line componen t s shou ld be examined

before start ing any repair.Refer to Group 22, Wheels and Tires, for additional

information.

DRIVELINE SNAPA snap or clunk noise when the vehicle is shifted

into gear (or the clutch engaged), can be caused by:• High engine idle speed

• 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/case clearance

The source of a snap or a clunk noise can be deter-mined with the assistance of a helper. Raise th e vehi-cle on a hoist with the wheels free to rotate. Instructthe helper to shift the transmission into gear. Listenfor the noise, a mechan ics stethoscope is h elpful inisolating the source of a noise.

TRAC–LOK DIFFERENTIAL NOISEThe most common problem is a chatter noise when

tu rn ing corn ers. Before removing a Tra c-lok un it forrepair, drain, f lush and refil l the axle with the spec-i fied lubr icant . Refer to Lubr icant change in th isGroup.

A container of Mopar Trac-lok Lu bricant (frictionmodifier) should be added after r epair service or alubricant change.

After changing the lubricant, drive the vehicle andmake 10 to 12 slow, figure–eight turns. This maneu-ver wil l pump lubr icant through the clu tches . Thiswill correct the condition in most instances. If thechat ter persists, clutch damage could have occurr ed.


DIAGNOSIS AND T ESTING (Continued)











TRAC–LOK TEST

WARNING: WHEN SERVICING VEHICLES WITH ATRAC–LOK DIFFERENTIAL DO NOT USE THEENGINE TO TURN THE AXLE AND WHEELS. BOTHREAR WHEELS MUST BE RAISED AND THE VEHI-

CLE SUPPORTED. A TRAC–LOK AXLE CAN EXERTENOUGH FORCE IF ONE WHEEL IS IN CONTACTWITH A SURFACE TO CAUSE THE VEHICLE TOMOVE.

The differential can be tested without removing thedifferential case by measuring rotating torque. Makesure b rakes a re not d ragging dur ing th is measure -ment .

(1) Place blocks in front and rear of both frontwheels.

(2) Raise one r ear wheel unt il i t is completely off the ground.

(3) Engine off, transmission in neutral , and park-ing brake off.(4) Remove wheel a nd bolt Special Tool 6790 to

studs.(5) Use torque wrench on specia l tool to rota te

wheel and read rotating torque (Fig. 5).

(6) I f ro ta t ing torque is less than 22 N·m (30 f t .lbs .) or more than 271 N·m (200 ft . lbs .) on e ither

wheel the unit should be serviced.

SERVICE PROCEDURES

LUBRICANT CHANGE(1) Raise and support the vehicle.(2) Remove the lubr icant fi ll hole p lug from the

differential housing cover.(3) Remove the different ia l housing cover and

drain the lubricant from the housing.

(4) Clean the housing cavi ty with a flushing oi l,light engine oil or lint free cloth. Do no t u se wa te r,s t eam, ke rosene o r gaso l ine fo r c l ean ing .

(5) Remove the original sealant from the housingand cover surfaces.

(6) Apply a bead of Mopar Silicone Ru bber Seal-

ant, or equivalent, to t he housing cover (Fig. 6).

In s ta ll t h e h o u si n g c o ve r w i th i n 5 m i nu t e sa f t e r app ly ing the sea l an t .

(7) Ins ta l l the cover and any ident ifica t ion tag .Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.

(8 ) For Trac–Lok d iffe ren t ia l s, a quan t ity of Mopar Trac–Lok lubricant (friction modifier) , orequivalent , must be a dded after repair service or a

lubricant chan ge. Refer to t he General Informat ionsection of this group for the quantity necessary.

(9) Fi ll d ifferent ia l with Mopar Hypoid GearLubr icant , or equivalent , to bot tom of the fi ll p lughole. Refer to the Lubr icant Specifica t ions in th isgroup for the quant ity necessary.

CAUTION: Overfilling the differential can result inlubricant foaming and overheating.

(10) Insta ll the fill hole plug an d lower t he vehicle.(11) Trac–Lok differen tia l equipped vehicles should

be road tested by making 10 to 12 slow figure-eight

t u rn s. Th is m a neu ver will p um p t h e lu br ica n tthrough the clutch discs to eliminate a possible chat-ter noise complaint.

REMOVAL AN D I NSTALLATI ON

REAR AXLE

REMOVAL

(1) Raise and support the vehicle.

Fig. 5 Trac-loc Test

Fig. 6 Apply Sealant





(2) Posit ion a suitable l ift ing device under theaxle.

(3) Secure axle to device.(4) Remove the wheels and t ires.(5) Remove the brake rotors and calipers from the

axle. Refer to Group 5, Brakes, for proper procedures.

(6) Disconnect the vent hose from the axle shafttube.(7) Mark the propeller shaft and yokes for instal-

lation alignment reference.(8) Remove pr opeller sha ft.(9) Disconnect stabilizer bar links.(10) Disconnect shock absorbers from axle.(11) Disconnect tra ck bar.(12) Disconnect upper and lower suspension arms

from the axle brackets.(13) Separate the axle from the vehicle.

INSTALLATION

NOTE: The weight of the vehicle must be sup-ported by the springs before suspension arms andtrack bar fasteners can be tightened. If the springsare not at their normal ride position, vehicle rideheight and handling could be affected.

(1) Raise the axle with lifting device and align coilsprings.

(2) Posit ion the upper and lower suspension armson the axle brackets . Ins ta ll n uts and bol ts, do nottighten bolts at this t ime.

(3) Ins ta l l t rack bar and a t tachment bol ts , do not

tighten bolts at this t ime.(4) Ins ta l l shock absorber and t ighten nuts to 60N·m (44 ft. lbs.) torque

(5) Ins ta l l s tabil izer bar l ink and t ighten nuts to36 N·m (27 ft. lbs.) torque

(6) Ins ta l l the brake rotors and cal ipers. Refer toGroup 5, Brakes, for proper procedures.

(7) Install axle vent hose(8) Align propeller shaft and pinion yoke reference

marks. Install U-joint straps and bolts t ighten to 19N·m (14 ft. lbs.) torque

(9) Install the wheels and t ires.(10) Check and add gear lubricant.

(11) Remove lifting device from a xle a nd lower thevehicle.

(12) Tighten lower suspension arms bol ts to 177N·m (130 ft. lbs.) torque.

(13) Tighten upper suspension arms bol ts to 75N·m (55 ft. lbs.) torque.

(14) Tighten track bar bolts to 100 N·m (74 ft. lbs.)torque.

PINION SHAFT SEAL REPLACEMENT

REMOVAL

(1) Raise and support the vehicle.(2) Remove wheel an d t ire a ssemblies.(3) Remove rear brak e rotors a nd calipers. Refer to

Group 5, Brakes, for proper procedures.(4) Mark the propeller shaft and pinion yoke forinstallation reference.

(5) Remove th e propeller sh aft from th e yoke.(6) Rotate the pinion gear three or four t imes.(7 ) Measure the amoun t of t orque necessa ry to

rota te the p inion gear with an (in . lbs .) d ia l -typetorque wrench. Record the torque reading for instal-lation reference.

(8) Using a short piece of pipe an d Holder 6958 tohold the p in ion yoke , r emove the p in ion nu t andwasher (Fig. 7).

(9) Use Remover C-452 and Wrench C-3281 to

remove the pinion yoke (Fig. 8).

(10) Use Remover 7794A and s lide hammer toremove the pinion shaft seal (Fig. 9).

Fig. 7 Pinion Yoke Holder

Fig. 8 Pinion Yoke Removal


REMOVAL AND INSTALLATION (Continued)



INSTALLATION

(1) Apply a l ight coating of gear lubricant on thelip of pinion seal. Install seal with Installer D-163and Handle C-4171 (Fig. 10).

(2) Install yoke on the pinion gear with InstallerC-3718.

CAUTION: Do not exceed the minimum tighteningtorque when installing the pinion yoke retaining nutat this point. Damage to collapsible spacer or bear-ings may result.

(3) Ins ta l l a new nut on the pinion gear. Tightent h e n u t o n ly e n o u gh t o r e m ov e t h e s h a ft e n dplay.

(4 ) Rota t e the p in ion sha ft u s ing an (in . lb s. )torque wrench. Rotating resistance torque should beequal to the reading recorded dur ing removal , p lusan additional 0.56 N·m (5 in. lbs.) (Fig. 11).

(5) If the rotating torque is low, use Holder 6958 tohold the pinion yoke (Fig. 12), and tighten the pinionsha ft nu t in 6 .8 N ·m (5 ft . lb s.) i ncremen t s un t ilproper rotating t orque is a chieved.

CAUTION: If the maximum tightening torque isreached prior to reaching the required rotatingtorque, the collapsible spacer may have been dam-aged. Replace the collapsible spacer.

(6 ) Align the ins t a lla t ion r e fe rence marks andinstall the propeller shaft .

(7) Add gear lubricant to t he differential h ousing,if necessary. Refer to the Lubricant Specifications forgear lubricant requirements.

(8 ) Inst a ll b rake rotor s and ca liper s . Refe r t oGroup 5, Brakes, for proper procedures.

(9) Install wheel and t ire assemblies.(10) Lower the vehicle.

Fig. 9 Seal Removal

Fig. 10 Pinion Seal Installation

Fig. 11 Check Pinion Rotation Torque

Fig. 12 Tightening Pinion Shaft Nut





COLLAPSIBLE SPACER

REMOVAL W/PINION INSTALLED

(1) Raise and support the vehicle.(2) Remove wheel and t ire assemblies.(3) Remove rear brake rotors and calipers. Refer to

Group 5, Brakes, for proper procedures.(4) Mark the propeller shaft and pinion yoke forinstallation reference.

(5) Remove the propeller shaft from the yoke.(6) Rotate the pinion gear three or four t imes.(7 ) Measure the amoun t of t orque necessa ry to

rota t e the p in ion gea r with an in . lb s. d ia l-typetorque wrench. Record the torque reading for instal-lation reference.

(8) Using a short piece of pipe and Holder 6958 tohold the p in ion yoke, r emove the p in ion nu t andwasher (Fig. 13).

(9) Use Remover C-452 and Wrench C-3281 to

remove the pinion yoke (Fig. 14).(10) Use Remover 7794-A an d s lide hammer to

remove the pinion shaft seal (Fig. 15).(11) Remove the front pinion bearing using a pair

of suitable pick tools to pull the bearing stra ight off the pinion gear shaft . I t may be necessary to l ightlytap the end of the pinion gear with a rawhide or rub-ber mallet if the bearing becomes bound on the pin-ion shaft.

(12) Remove th e collapsible spa cer.

REMOVAL W/PINION REMOVAL

(1) Raise and support the vehicle.(2) Remove wheel and t ire assemblies.(3) Remove rear brake rotors and calipers. Refer to

Group 5, Brakes, for proper procedures.(4) Mark the propeller shaft and pinion yoke for

installation reference.(5) Remove the propeller shaft from the yoke.(6) Rotate the pinion gear three or four t imes.(7 ) Measure the amoun t of t orque necessa ry to

rota t e the p in ion gea r with an in . lb s. d ia l-typetorque wrench. Record the torque reading for instal-lation reference.

(8) Remove differential assembly from axle hous-ing.

(9) Using Holder 6958 to hold yoke and a shor tlength of 1 in. pipe, remove the pinion yoke nut andwasher (Fig. 13).

(10) Using Remover C–452 and Wrench C–3281,remove the pinion yoke from pinion shaft (Fig. 14).

(11) Remove the pinion gear from housing (Fig.16). Catch the pinion with your hand to prevent i tfrom falling a nd being damaged.

(12) Remove collapsible spa cer from pinion sha ft.

INSTALLATION

(1) Insta ll a n ew collapsible preload spacer on pin-ion shaft (Fig. 17).

(2) If pinion gear wa s r emoved, install pinion gearin housing.

(3) Insta ll pinion front bearing. Apply a light coat-ing of gear lubricant on the l ip of pinion seal. Installseal wi th Ins ta ller D–163 and Handle C–4171 (Fig.18).



Fig. 15 Seal Removal





(4) Inst all yoke with Installer C–3718 an d holder6958 (Fig. 19).

(5) If the original pinion bearings are being used,install differential assembly and axle shafts, if neces-sary.

NOTE: If new pinion bearings were installed, do notinstall the differential assembly and axle shafts untilafter the pinion bearing preload and rotating torqueare set.

(6) Ins ta l l the yoke washer and a new nut on thepinion gear. Tighten the nut to 298 N·m (220 ft . lbs.)minimum. Do no t ove r– t igh ten . Maximum torqueis 380 N·m (280 ft. lbs.).

CAUTION: Never loosen pinion gear nut todecrease pinion gear bearing rotating torque andnever exceed specified preload torque. If preloadtorque is exceeded a new collapsible spacer mustbe installed. The torque sequence will have to berepeated.

NOTE: A new collapsible spacer will start to crushat around 265 ft. lbs. torque. If the spacer requiresmore than 280 ft. lbs. torque to crush, the collaps-ible spacer is defective.

(7) Using yoke h older 6958, a short length of 1 in.p ipe, and a torque wrench set a t 380 N ·m (280 ft .lbs.), crush collapsible spacer until bearing end playis taken up (Fig. 20).

(8) Slowly t ighten the nut in 6 .8 N·m (5 ft . lbs .)incremen t s un t il t he rot a t ing torque is ach ieved.

Fig. 16 Remove Pinion Gear

Fig. 17 Collapsible Preload Spacer


Fig. 19 Pinion Yoke Installation





Measure the rotating torque frequently to avoid overcrushing the collapsible spa cer (Fig. 21).

(9 ) Check rot a t ing torque with an inch poundtorque wrench (Fig. 21). The torque necessary torotate the pinion gear should be:

• Original Bearings — The reading recorded dur-ing removal, plus an additional 0.56 N·m (5 in. lbs.).

• New Bearings — 2 to 5 N·m (15 to 35 in. lbs.) .

(10) Insta ll differential a ssembly and axle sha fts,if necessary.

(11) Align marks made previously on yoke and pro-peller shaft and install propeller shaft .

(12) Install rear brake r otors and calipers. Refer t oGroup 5 Brakes, for proper procedures.

(13) Add gear lubr icant , i f necessary. Refer toLubricant Specifications of this section for lubricantrequirements.

(14) Install wheel and t ire a ssemblies.(15) Lower vehicle.

AXLE SHAFT

REMOVAL

(1 ) Ra ise and suppor t veh icl e. Ensure tha t t hetransmission is in neutral .

(2) Remove rear wheel and t ire.(3) Remove bra ke caliper an d rotor. Refer t o Group

5, Brakes, for proper procedure.(4) Clean all foreign material from housing cover

area .(5) Loosen housing cover bol ts. Drain lubr icant

from the housing and axle shaft tubes. Remove hous-ing cover.

(6) Rota te d ifferent ia l case so that p inion mategear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from different ia lcase (Fig. 22).

(7) Push axle shaf t inward and remove axle shaf tC–clip lock from the axle shaft (Fig. 23).

(8) Remove axle sha ft . Use care to prevent damageto axle shaft bearing and seal, which will remain inaxle shaft tube.

(9) Inspect axle shaft seal for leakage or damage.(10) Inspect roller bearing contact surface on axle

shaft for signs of brinelling, gall ing and pit t ing. If any of th ese conditions exist , th e axle shaft and/orbearing and seal must be replaced.

INSTALLATION

(1) Lubr icate bear ing bore an d seal l ip with gearlubr icant . Inser t axle shaft through seal, bear ing,and engage i t in to s ide gear splines . U s e c a r e t o

Fig. 20 Tightening Pinion Nut

Fig. 21 Check Pinion Gear Rotation Torque

Fig. 22 Mate Shaft Lock Screw





preven t sha f t sp l ines f rom damag ing ax le sha f tsea l l i p .

(2) Inser t C–cl ip lock in end of axle shaft . Pushaxle shaft outward to seat C–clip lock in side gear.

(3) Insert pinion mate shaft into differential caseand through thrus t washers and pinion gears .

(4) Align hole in shaft with hole in the differentialcase and insta l l lock screw with Loct i te on t h ethreads . Tighten lock screw to 19 N·m (14 ft . lbs .)torque.

(5) Install cover and add fluid. Refer to LubricantChange procedure in this section for procedure andlubricant requirements.

(6) Install brake caliper and rotor. Refer to Group5, Brakes, for proper procedures.

(7) Install wheel and t ire.(8) Lower vehicle.

AXLE SHAFT SEAL AND BEARING

REMOVAL

(1) Remove the axle shaft .(2) Remove the axle shaft seal from the end of the

axle shaf t tube wi th a smal l pry bar.

NOTE: The seal and bearing can be removed at thesame time with the bearing removal tool.

(3) Remove th e axle shaft bear ing f rom the tube(Fig. 24) with Bearing Removal Tool Set 6310.

(4) Inspect the axle shaft tube bore for roughnessand burrs. Remove as necessary.

INSTALLATION

D o n o t i n st al l t h e o ri gi n al a x le s h a ft s e a l.A lways in s t a l l a new sea l .

(1) Wipe the bore in the axle shaft tube clean.(2) Ins ta l l a xle shaft bear ing with Ins ta ller 6436

a n d H a n dle C –4 17 1. E n su r e p a rt n u m be r on t h ebearing is against the installer.

(3) Ins ta l l the new axle shaft sea l (Fig . 25) withInstaller 6437 and Handle C–4171.

(4) Install the axle shaft .

DIFFERENTIAL

REMOVAL

(1) Remove a xle shafts.(2) Note the orientation of th e installation refer-

ence le t ters s tamped on the bear ing caps and hous-ing machined sealing surface (Fig. 26).

(3) Remove t he different ial bearing caps.(4) Position Spreader W–129–B with t he t ool dowel

pins seated in the locating holes (Fig. 27).

Fig. 23 Axle Shaft C–Clip Lock

Fig. 24 Axle Shaft Bearing Removal Tool

Fig. 25 Axle Shaft Seal Installation





(5) Ins ta l l the hold down clamps and t ighten thetool turnbuckle finger–tight.

(6) Install a pilot stud at the left side of the differ-ential housing. Attach dial indicator to housing pilotstud. Load the indicator plunger against the oppositeside of the housing (Fig. 27) and zero the indicator.

(7 ) Sepa ra t e the hous ing enough to r emove thecase from the housing. Measure the distan ce with t hedial indicator (Fig. 27).

CAUTION: Do not spread over 0.38 mm (0.015 in). Ifthe housing is over–separated, it could be distortedor damaged.

(8) Remove the dial indicator.(9) Pr y the differential case loose from the hous-

ing. To prevent damage, p ivot on housing with theend of the pry bar against spreader (Fig. 28).

(10) Remove the case from housing. Mark or tagbearing cups and outboard shim(s)/spacer(s) (selectedthickness) to indicate which side they were removedfrom.

DIFFERENTIAL INSTALLATION

(1) Position Spreader W–129–B with t he t ool dowelpins seated in the locating holes (Fig. 27). Inst all thehold down clamps an d t ighten the tool turnbucklefinger–tight.

(2) Install a pilot stud at the left side of the differ-ential housing. Attach dial indicator to housing pilotstud. Load the indicator plunger against the oppositeside of the housing (Fig. 27) and zero the indicator.

(3) Separate the housing enough to install the casein the housing. Measure the d is tance with the d ia lindicator (Fig. 27).

CAUTION: Do not spread over 0.51 mm (0.020 in). Ifthe housing is over–separated, it could be distortedor damaged.

(4) Remove t he dial indicator.(5) Install differential and outboard shim(s)/spac-

er(s) (selected thickness) in housing.(6) Install case in the housing. Tap th e differential

case wi th a rawhide or rubber mal le t to ensure thebearings are fully seated in the differential h ousing(Fig. 29).

(7) Remove the spreader.(8) Insta ll the bearing caps at their original loca-

t ions (Fig. 30). Tighten the bear ing cap bol ts to 77N·m (57 ft. lbs.) torque.

(9) Install axle shafts.

Fig. 26 Bearing Cap Identification

Fig. 27 Spread Differential Housing

Fig. 28 Differential Removal





DIFFERENTIAL SIDE BEARINGS

REMOVAL

(1) Remove differential case from axle housing.(2) Remove the bearings from the differential case

with Pu ller/Press C-293-PA, C-293-42 Adapters andPlug C-293-3 (Fig. 31).

DIFFERENTIAL SIDE BEARING INSTALLATION

(1) Using tool C-4340 with handle C-4171, installdifferential side bearings (Fig. 32).

(2) Install differential case in axle housing.

Fig. 29 Differential Installation

Fig. 30 Differential Bearing Cap Reference Letters

Fig. 31 Differential Bearing Removal

Fig. 32 Install Differential Side Bearings





RING GEAR

NOTE: The ring and pinion gears are service in amatched set. Do not replace the ring gear withoutreplacing the pinion gear.

REMOVAL

(1) Remove differential case from axle housing.(2) Clamp Side Gear Holding Tool 6963-A in a vise.(3) Posit ion deferential case on the holding tool

(Fig. 33).(4) Place shop towels around differential to cover

vise in order to prevent damage to r ing gear whenremoved.

(5) Remove and discard the bolts holding the ringgear to differential case.

(6) Using a soft hammer, drive ring gear from dif-ferential case.

RING GEAR INSTALLATION

CAUTION: Do not reuse the bolts that held the ringgear to the differential case. The bolts can fracturecausing extensive damage.

(1) Invert the differential case on Side Gear Hold-ing Tool 6963-A.

(2) Posit ion ring gear on the differential case andstart two new ring gear bolts. This will provide case-–to–ring gear bolt hole alignment.

(3) Invert the differential case on Side Gear Hold-ing Tool 6963-A.

(4 ) Inst a ll new r ing gea r bolt s and a lt e rna telytighten to 95–122 N ·m (70–90 ft . lbs.) torque (Fig.34).

(5) Install differential in axle housing and verifydifferential side bearing preload, gear mesh, and con-tac t pat tern .

PINION GEAR

REMOVAL(1) Remove differential assembly from axle hous-

ing.(2 ) Mark p in ion yoke and p ropel le r sha ft for

installation alignment.(3) Disconnect propeller shaft from pinion yoke.

Using suitable wire, tie propeller shaft to underbody.(4) Using Holder 6958 to hold yoke and a shor t

length of 1 in. pipe, remove the pinion yoke nut andwasher (Fig. 35).

(5) Using Remover C–452 and Wrench C–3281,remove the pinion yoke from pinion shaft (Fig. 36).

(6) Remove t he pinion gear from housing (Fig. 37).Catch the pinion wi th your hand to prevent i t f romfalling and being damaged.

(7) Remove the pinion seal with a sl ide ha mmer orpry out with bar.

(8) Remove oil sl inger, if equipped, a nd the frontpinion bearing.

(9 ) Remove the fron t p in ion bea r ing cup withRemover D-103 and Handle C–4171 (Fig. 38).

(10) Remove the rear bear ing cup from housing(Fig. 39). Use Remover C-4307 and Handle C–4171.

Fig. 33 Side Gear Holding Tool 6963-A

Fig. 34 Ring Gear Bolt Installation





(11) Remove the collapsible preload spacer (Fig.40).

(12) Remove the rear bearing from th e pinion withPuller/Press C–293-PA and Adapters C–293–42 (Fig.41).

P lace 4 adap te r b locks so they do no t damaget h e b e a ri n g c a g e .

(13) Remove the pinion depth shims from the pin-ion gea r sha ft . Record the tot a l t h ickness of t hedepth shims.



Fig. 37 Remove Pinion Gear

Fig. 38 Front Bearing Cup Removal

Fig. 39 Rear Bearing Cup Removal





PINION GEAR INSTALLATION

(1) Apply Mopar Door Ease stick lubricant to out-s ide surface of bear ing cup. Ins ta l l t he p inion rearbear ing cup with Ins ta ller C–4308 an d Driver Han-dle C–4171 (Fig. 42). Ensure cup is correctly seated.

(2) Apply Mopar Door Ease stick lubricant to out-side surface of bearing cup. Inst all th e pinion frontbearing cup with Installer D–129 and Han dle C–4171(Fig. 43).

(3) Insta ll pinion front bearing a nd oil sl inger, if equipped. Apply a l ight coating of gear lubricant onthe lip of p in ion sea l. In st a ll s ea l w ith Inst a ll erD–163 and Handle C–4171 (Fig. 44).

NOTE: Pinion depth shims are placed between therear pinion bearing cone and pinion gear to achieveproper ring and pinion gear mesh. If the factoryinstalled ring and pinion gears are reused, the pin-ion depth shim should not require replacement oradjustment. Refer to Pinion Gear Depth paragraphin this section to select the proper thickness shimbefore installing rear pinion bearing cone.

(4) Place the proper thickness pinion depth shimon the pinion gear.

Fig. 40 Collapsible Spacer

Fig. 41 Inner Bearing Removal

Fig. 42 Pinion Rear Bearing Cup Installation

Fig. 43 Pinion Front Bearing Cup Installation





(5) Install the rear bearing (and slinger if used) onthe pinion gear with Installer 6448 (Fig. 45).

(6) Install a new collapsible preload spacer on pin-ion shaft (Fig. 46).

(7) Install pinion gear in housing.(8) Inst all yoke with Installer C–3718 an d holder

6958 (Fig. 47).(9) Ins ta l l the yoke washer and a new nut on thepinion gear. Tighten the nut to 298 N·m (220 ft . lbs.)minimum. Do no t ove r– t igh ten . Maximum torqueis 380 N·m (280 ft. lbs.).

CAUTION: Never loosen pinion gear nut todecrease pinion gear bearing preload torque andnever exceed specified preload torque. If preloadtorque is exceeded a new collapsible spacer mustbe installed. The torque sequence will have to berepeated.

NOTE: A new collapsible spacer will start to crushat around 265 ft. lbs. torque. If the spacer requiresmore than 280 ft. lbs. torque to crush, the collaps-ible spacer is defective.

(10) Using yoke h older 6958, a short length of 1 in.p ipe, and a torque wrench set a t 380 N ·m (280 ft .lbs.), crush collapsible spacer until bearing end playis taken up (Fig. 48).

(11) Slowly t ighten the nut in 6.8 N·m (5 ft . lbs.)incremen t s un t il t he rot a t ing torque is ach ieved.Measure the rotating torque frequently to avoid overcrushing the collapsible spacer (Fig. 49).

(12) Check bear ing rota t ing torque with an inchpound torque wrench (Fig. 49). The torque n ecessaryto rotate the pinion gear should be:


Fig. 45 Shaft Rear Bearing Installation

Fig. 46 Collapsible Preload Spacer

Fig. 47 Pinion Yoke Installation





• Orig ina l Bea r ings — 1 to 3 N ·m (10 to 20 in .lbs.).

• New Bearings — 2 to 5 N·m (15 to 35 in. lbs.) .

(13) Al ign previously made marks on yoke andpropeller shaft and install propeller shaft .

(14) Install differential housing into t he axle hous-ing.

FINAL ASSEMBLY(1) Scrape the res idual sealant from the housing

and cover mating surfaces. Clean the mating surfaceswith mineral spirits. Apply a bead of Mopar SiliconeRubber Sealant, or equivalent, on the housing cover(Fig. 50).

In s ta ll t h e h o u si n g c o ve r w i th i n 5 m i nu t e sa f t e r app ly ing the sea l an t .

(2) Ins ta ll the cover on the different ia l with theattaching bolts. Install the identification tag. Tightenthe cover bolts to 41 N·m (30 ft. lbs.) torque.

CAUTION: Overfilling the differential can result inlubricant foaming and overheating.

(3) Refill the differential h ousing with gear lubri-cant . Refer to the Lubr icant Specifica t ions for thegear lubricant requirements.

(4) Install t he fi ll h ole plug.

DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL

DISASSEMBLE

(1) Remove pinion gear ma te sh aft lock screw (Fig.51).

(2) Remove pinion gear m ate shaft .(3) Rota te the d ifferent ia l s ide gears and remove

the pinion mate gears and thrus t washers (Fig. 52).(4) Remove the different ia l s ide gears and thrus t

washers.

DIFFERENTIAL ASSEMBLE

(1) Ins ta ll the d ifferent ia l s ide gears and thrus twashers.

(2) Ins ta ll the p inion mate gears and thrus t wash-ers.

(3) Install the pinion gear mate shaft .

Fig. 48 Tightening Pinion Nut

Fig. 49 Check Pinion Gear Rotation Torque

Fig. 50 Typical Housing Cover With Sealant





(4) Al ign the hole in the p inion gear mate shaftwith the hole in the differential case and install thepinion gear mate shaft lock screw.

(5) Lubr icate a l l d ifferent ia l components withhypoid gear lubricant.

TRAC-LOK DIFFERENTIALThe Trac–Lok differential components are i llus-

trat ed in (Fig. 53). Refer to th is i l lustra tion duringrepair service.

DISASSEMBLY

(1) Clamp Side Gear Holding Tool 6963–A in avise.

Fig. 53 Trac–Lok Differential Components

Fig. 51 Pinion Gear Mate Shaft Lock Screw

Fig. 52 Pinion Mate Gear Removal


DISASSEMBLY AN D ASSEMBLY (Continued)



(2) Posit ion the different ia l case on Side GearHolding Tool 6963-A (Fig. 54).

(3 ) Remove r ing gea r, if necessa ry. R ing gea rremoval i s necessary only i f the r ing gear i s to bereplaced. The Trac-Lok differential can be servicedwith the ring gear installed.

(4) Remove th e pinion gear mate shaft lock screw(Fig. 55).

(5) Remove t he pinion gear mate shaft . I f neces-sary, use a drift and hammer (Fig. 56).

(6) Install an d lubricate Step P late C–4487–1 (Fig.57).

(7) Assemble Threaded Adapter C–4487–3 into tops ide gea r. Thread Forcing Screw C–4487–2 in toadapter until i t becomes centered in adapter plate.

(8) P os it ion a s ma ll s cr ew d r ive r in s lot of Threaded Adapter C–4487–3 (Fig. 58) to preventadapter from turning.

(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.)(maximum) to compress Bellevil le springs in clutchpacks (Fig. 59).

(10 ) U sin g a n a p pr op ria t e s ize fee le r ga u ge ,remove thrust washers from behind the pinion gears(Fig. 60).

(11) Inser t Turning Bar C–4487–4 in case (Fig.61).

(12) Loosen the Forcing Screw C-4487-2 in smallincrements until the clutch pack tension is r elievedand the differential case can be tur ned u sing TurningBar C-4487-4.

(13) Rotate differential case u ntil t he pinion gearscan be removed.

Fig. 54 Differential Case Holding Tool

Fig. 55 Mate Shaft Lock Screw

Fig. 56 Mate Shaft Removal

Fig. 57 Step Plate Tool Installation





(14) Remove pinion gears from different ial case.(15) Remove Forcing Screw C–4487-2, Step Plate

C-4487-1, and Threaded Adapter C-4487-3.(16) Remove top side gear, clutch pack retainer,

and clutch pack. Keep plates in correct order duringremoval (Fig. 62).

(17) Remove different ial case from Side Gea r Hold-ing Tool 6963-A. Remove s ide gear, clu tch pack r e t a ine r, and clu t ch pack . Keep p la t e s in cor rectorder during removal.

ASSEMBLY

NOTE: The clutch discs are replaceable as com-plete sets only. If one clutch disc pack is damaged,both packs must be replaced.

Lubr ica t e each componen t with gea r lub r ican tbefore assembly.

(1) As se mb le t h e clu t ch d is cs in t o p a ck s a n dsecure disc packs with retaining clips (Fig. 63).

(2) Posit ion assembled clutch disc packs on theside gear hubs.

(3) Ins ta ll c lu tch pack and s ide gear in t he r inggear side of t he differential case (Fig. 64). B e s u r ec lu t c h p a c k r e ta i n in g c l ip s r e m a in i n p o s it i ona n d a r e s e a t e d i n t h e c a s e p o c k e t s .

(4) Posit ion the different ia l case on Side GearHolding Tool 6963-A.

(5) Install lubricated Step Plate C–4487–1 on sidegear (Fig. 65).

(6) Install the upper side gear and clutch disc pack (Fig. 65).

Fig. 58 Threaded Adapter Installation

Fig. 59 Tighten Belleville Spring Compressor Tool

Fig. 60 Remove Pinion Gear Thrust Washer

Fig. 61 Pinion Gear Removal





(7) Hold assembly in posit ion. Inser t ThreadedAdapter C–4487–3 into top side gear.

(8) Insert Forcing Screw C–4487–2.(9) Tighten forcing screw tool to slightly compress

clut ch discs.(10) P lace pinion gears in posit ion in s ide gears

and verify that the pinion mate shaft hole is aligned.(11) Rotate case with Turning Bar C–4487–4 until

the p inion mate shaft holes in p inion gears a l ignwith holes in case . I t may be n ecessary to s l ight ly

tighten the forcing screw in order to install the pin-ion gears.

(12) Tighten forcing screw t o 122 N ·m (90 ft. lbs.)to compress the Belleville springs.

(13) Lubr icate and ins ta ll thrus t washers behindpinion gears and a l ign washers with a smal l screwdriver. Insert mate shaft into each pinion gear to ver-ify alignment.

(14) Remove forcing screw, threaded adapter, andstep plate.

(15) Install pinion gear ma te sha ft and align h olesin shaf t and case .

Fig. 62 Side Gear & Clutch Disc Removal

Fig. 63 Clutch Disc Pack

Fig. 64 Clutch Discs & Lower Side Gear Installation

Fig. 65 Upper Side Gear & Clutch Disc Pack Installation





(16) Install the pinion mate shaft lock screw fingertight to h old sh aft during differential installation.

I f r ep lacemen t gea r s and th rus t w ashe r s we rei n st al le d , i t i s n o t n e c e ss a ry t o m e a su re t h eg ea r b ac kla sh . Co rre ct fi t is d ue t o c lo semach in ing to l e rances du r ing manufac tu re .

(17) Lubr icate a l l d ifferent ia l components withhypoid gear lubricant.

CLEANING AND INSPECTION

AXLE COMPONENTSWash different ial components with cleaning solvent

and dry with compressed air. D o n o t s t e a m c l e a nthe d i f f e ren t i a l componen t s .

Wash bearings with solvent and towel dry, or drywith compressed a i r. DO NOT spin bear ings withcompressed a i r. Cu p an d be arin g m ust be

rep laced a s ma tched se t s on ly.Clean axle shaft tubes and oil channels in housing.Inspect for;• Smooth appearance with no broken/dented surfaces

on the bearing rollers or the roller contact surfaces• Bearing cups must not be distorted or cracked• Machined su rfaces sh ould be smooth and with-

out any raised edges• Raised metal on shoulders of cup bores should

be removed wi th a hand s tone• Wear and damage to p in ion gea r ma te sha ft ,

pinion gears, side gears and thrust washers. Replaceas a matched set only.

•

Ring and pinion gear for worn and chipped teeth• Ring gear for damaged bolt threads. Replaced as

a matched set only.• Pinion yoke for cracks , worn splines , p it ted

areas , and a rough/corroded seal contact surface .Repair or replace as necessary.

• Preload shims for damage and distortion. Installnew shims if necessary.

TRAC-LOKClean all components in cleaning solvent. Dry com-

ponents with compressed a i r. Inspect clu tch pack pla tes for wear, scor ing or damage. Replace both

clutch packs if any one component in either pack isdamaged. Inspect side and pinion gears. Replace anygea r tha t is worn , cracked , ch ipped or damaged.Inspect differential case and pinion shaft . Replace if worn or damaged.

PRESOAK PLATES AND DISC

Plates and discs with fiber coating (no grooves orlines) must be pr esoaked in Friction Modifier beforeassembly. Soak plates and discs for a minimum of 20minutes.

ADJUSTMENTS

PINION GEAR DEPTH

GENERAL IN FORMATI ON

Ring and p in ion gea r s a re supplied a s ma tched

sets only. The identifying numbers for the ring a ndpinion gear are etched into the face of each gear (Fig.66). A plus (+) number, minus (–) num ber or zero (0)is etched into the face of the pinion gear. This num-ber is t he amoun t (in thousandths of an inch ) thedep th var ie s from the s t anda rd dep th set t ing of apinion etched with a (0). The standar d sett ing fromthe center l ine of the ring gear t o the back face of thepinion is 109.52 mm (4.312 in.) . The standard depthprov ides the bes t t eeth con tact pa t t ern . Refe r t oBacklash and Contact Pattern Analysis Paragraph inthis section for additional information.

Com pen sa t ion for p in ion d ep th va r ia n ce isachieved with se lect shims. The shims are p lacedunder the inner pinion bearing cone (Fig. 67).

Fig. 66 Pinion Gear ID Numbers

Fig. 67 Shim Locations





If a new gear set is being installed, note the depthvar iance e tched in to both the or iginal a nd replace-ment p inion gear. Add or subtract the th ickness of the original depth shims to compensate for the differ-ence in the depth variances. Refer to the Depth Vari-ance charts.

Note where Old and New Pinion Marking columnsin te r sect . In t er sect ing figu re r epresen t s p lus orminus amount needed.

Note the e tched number on the face of the dr ivepinion gear (–1, –2, 0, +1, +2, etc.). The numbers rep-resent thousands of an inch deviation from the stan-dard. If the number is negative, add that value to therequired thickness of the depth shim(s). If the num-ber is positive, subtract that value from the thicknessof the depth shim(s). If the number is 0 no change isnecessary. Refer to t he Pinion Gear Depth VarianceChar t .

PINION DEPTH MEASUREMENT AND ADJUSTMENT

Measurements are taken with pinion cups and pin-ion bear ings ins ta lled in housing. Take measurementswith Pinion Gauge Set 6955, Dumm y Bear ing/ArborDisc Set 6956, and Dial Indicator C-3339 (Fig. 68).

(1) Assemble Pinion Height Block 6739, Pinion Block 6734, and rear pinion bearing onto Screw 6741 (Fig. 68).

(2) Inser t assembled height gauge components ,r ea r bea r ing and screw in to ax le hous ing th roughpinion bearing cups (Fig. 69).

(3 ) Ins t a ll fron t p in ion bea r ing and Cone 6740hand tight (Fig. 68).

(4) Pla ce Arbor Disc 6927 on Arbor D-115-3 in posi-t ion in axle housing side bearing cradles (Fig. 70).Install differential bearing caps on Arbor Discs andtighten cap bolts. Refer t o th e Torque Specificationsin this section.

NOTE: Arbor Discs 6927 have different step diame-ters to fit other axle sizes. Pick correct size step foraxle being serviced.

PINION GEAR DEPTH VARIANCE

Fig. 68 Pinion Gear Depth Gauge Tools—Typical


ADJUSTMENTS (Continued)



(5) Assemble Dial Indicator C-3339 into ScooterBlock D-115-2 and secure set screw.

(6) P lace S cooter Block/Dial Indicator in positionin axle housing so dial probe and scooter block areflush against the surface of the pinion height block.Hold scooter block in place and zero the dial indica-tor face to the pointer. Tighten dia l indicator facelock screw.

(7) With scooter block still in position against th epinion height block, slowly slide the dial indicatorp robe ove r the edge of the p in ion he igh t b lock .Observe how many revolutions counterclockwise thedial pointer tra vels (approximately 0.125 in.) to t heout-stop of the dial indicator.

(8) Sl ide the d ia l indicator probe across the gapbetween the pinion height b lock and the arbor barwith the scooter block against the pinion height block (Fig. 71). When the dial probe contacts the arbor bar,the d ia l poin te r w ill t u rn clockwise. Br ing d ia lpoin te r back to ze ro aga ins t t he a rbor ba r, do no tturn dial face. Continue moving the dial probe to the

crest of the arbor bar and record the highest reading.If the dial indicator can not a chieve t he zero reading,the rear bearing cup or the pinion depth gauge set isnot installed correctly.

(9) Select a shim equal to the dial indicator read-ing plus the drive pinion gear depth variance num ber

etched in the face of the pinion gear (Fig. 66) usingthe opposite sign on the variance number. For exam-ple, if the depth variance is –2, add +0.002 in. to thedial indicator reading.

(10) Remove the pinion depth gauge componentsfrom the axle housing

DIFFERENTIAL BEARING PRELOAD AND GEAR

BACKLASHDifferential side bearing preload and gear backlash is

achieved by selective shims inserted between the bearingcup and the axle housing. The proper shim thickness canbe determined using slip-fit dummy bearings 6929-A inplace of the differential side bearings and a dial indica-tor C-3339. Before proceeding with the differential bear-ing preload and gear backlash measurements, measurethe pinion gear depth and prepare the p inion gear forinsta l la t ion. Establishing proper p inion gear depth isessential to establishing gear backlash and tooth contactpatterns. After the overall shim thickness to t ake u p dif-fe ren t ia l s ide p lay i s measured , t he p in ion gea r i sinstalled, and the gear backlash shim thickness is mea-sured. The overall shim thickness is t he t otal of the dialindicator r eading, star t ing point shim t hickness, and thepreload specification added together. The gear backlashmeasurement determines the thickness of the shim usedon the ring gear side of th e differential case. Subtractthe gear backlash shim thickness from the total overallshim thickness and select that amount for the p iniongear side of the differential (Fig. 72).

Fig. 69 Pinion Height Block—Typical

Fig. 70 Gauge Tools In Housing—Typical

Fig. 71 Pinion Gear Depth Measurement—Typical





DIFFERENTIAL PRELOAD AND GEAR BACKLASH SHIM SELECTION

NOTE: It is difficult to salvage the differential sidebearings during the removal procedure. Installreplacement bearings if necessary.

(1) Remove side bearings from differential case.(2 ) I n st a ll r in g ge ar on d iffe re nt ia l ca s e a n d

tighten bolts to specification.(3) Install dummy side bearings 6929-A on differ-

ential case.(4) Install differential case in axle housing.(5) Insert 0.126 in. (3.2 mm) start ing point shims

between the dummy bearing and the axle housing on

side of differential (Fig. 73).

(6) Install the m arked bearing caps in th eir correctposit ions. Install and snug the bolts.

(7) Thread guide stud C-3288 into rear cover bolthole below ring gear (Fig. 74).

(8) At tach dia l indicator C-3339 to guide s tud.Posit ion the dial indicator plunger on a flat surface

between the ring gear bolt heads (Fig. 74).

(9) P ush and hold differential case to pinion gearside of axle housing.

(10) Zero dial indicat or face to pointer.(11) Pu sh and hold different ia l case to r ing gear

side of the axle housing.(12) Record dial indicator r eading.(13) Add the dial indicator reading to the start ing

point shim t hickness t o determine total shim thick-ness to achieve zero differential end play.

(14) Add 0 .012 in . (0 .3 mm) to the zero end playtota l. Th is new tot a l r epresen t s the th ickness of shims t o compress, or pr eload the new bearings whenthe differential is installed.

(15) Rotate dial indicator out of the way on guide

stud.(16) Remove different ia l case , dummy bear ings ,and start ing point shims from axle housing.

(17) Install pinion gear in a xle h ousing. Install theyoke and establish the correct pinion rotating torque.

(18) Install differential case and dummy bearingsin axle housing (without shims) and t ighten retainingcap bolts snug.

(19) Posit ion the dial indicator plunger on a flatsurface between the ring gear bolt heads (Fig. 74).

(20) Push and hold differential case t oward piniongear.

Fig. 72 Axle Adjustment Shim Locations

Fig. 73 Preload Measurement Starting Point Shim

Fig. 74 Differential Side play Measurement





(21) Zero dial indicator face to pointer.(22) Push and hold different ia l case to r ing gear

side of the axle housing.(23) Record dial indicator reading.(24) Subtract 0 .002 in . (0 .05 mm) from the dia l

indicator reading to compensate for backlash between

r ing and pinion gears . This to ta l i s the th ickness of shim required to achieve proper backlash.(25) Subtract the backlash shim thickness from the

total preload shim thickness. The remainder is the shimthickness required on the pinion side of the axle housing.

(26) Rotate dial indicator out of the way on guides tud.

(27) Remove differential case and dummy bearingsfrom axle housing.

(28) Ins ta l l n ew s ide bear ing cones and cups ondifferent ial case.

(29) Install spreader W-129-B on axle housing andspread axle opening enough to receive differential

case and side bearing shims.(30) P lace s ide bea r ing sh ims in ax le hous ing

against axle tube ends.(31) Install differential case in axle housing.(32) Remove spreader from axle housing.(33) Rota te the d ifferent ia l case severa l t imes to

seat the side bearings.(34) Posit ion the indicator plunger against a ring

gear tooth (Fig. 75).(35) Push and hold r ing gea r upward while not

allowing the pinion gear to rotate.(36) Zero dial indicator face to pointer.(37) Push and hold r ing gea r downward while not

allowing the pinion gear to rotate. Dial indicator read-ing should be between 0 .12 mm (0.005 in . ) and 0 .20mm (0.008 in.). If backlash is not within specificationst ransfer the necessary amount of shim thickness f romone side of the axle housing to the other (Fig. 76).

(38) Verify differential case and ring gear run outby measuring ring to pinion gear backlash at severallocations around the ring gear. Readings should notvary more than 0.05 mm (0.002 in.) . If readings varymore than specified, the ring gear or the differentialcase is defective.

After the proper backlash is achieved, perform theGear Contact Pattern Analysis procedure.

GEAR CONTACT PATTERN ANALYSISThe r ing and p in ion gea r t eeth con tact pa t t erns

wil l show i f the p inion gear depth is correct in theaxle housing. I t will also show if the ring gear back-lash has been adjusted correctly. The backlash can beadjus ted within speci fica t ions to achieve desi redtooth contact patterns.

(1) Apply a thin coat of hydrat ed ferric oxide, orequivalent , to the dr ive and coas t s ide of the r inggear teeth.

(2) Wrap, twist , and hold a shop towel around thepinion yoke to increase the turning resistance of thepinion gear. This will provide a more distinct contactpat tern .

(3) Using a boxed end wrench on a ring gear bolt ,Rotate the differential case one complete revolutionin both directions while a load is being applied fromshop towel.

The areas on the r ing gear tee th wi th the greates tdegree of contact against the pinion gear teeth willsqueegee the compound to the areas with the leas tamount of contact. Note and compare patterns on thering gear teeth to Gear Tooth Contact Patterns chart(Fig. 77) and adjust pinion depth and gear backlashas necessary.

Fig. 75 Ring Gear Backlash Measurement

Fig. 76 Backlash Shim Adjustment





Fig. 77 Gear Tooth Contact Patterns





SPECIFICATIONS

MODEL 44 AXLE

DESCRIP TION SP EC.Type . . . . . . . . . . . . . . . . . . . . .Semi-floating Hypoid

Axle Rat ios . . . . . . . . . . . . . . . . . . . . . . . . .3.55/3.73Ring Gear Diamete r . . . . . . . . . . .216 mm (8.5 in.)Gear Backlash . . . .0.13–0.20 mm (0.005–0.008 in.)P in ion Dep th . . . . . . . . . . . . .109.52 mm (4.312 in.)Brg. Pre load, Pinion

(New) . . . . . . . . . . .2.26–4.52 N ·m (20–40 in. lbs.)Brg. Pre load, Pinion

(Used) . . . . . . . . . . . . . . .1–3 N·m (10–20 in. lbs.)Maximum Carr ier Spread . . . . .0.51 mm (0.020 in.

TORQUE

DESCRIP TION TORQUE

Bolts, Diff. Cover . . . . . . . . . . . .41 N·m (30 ft. lbs.)Bol ts , Diff. Bear ing Cap . . . . . .85 N·m (63 ft. lbs.)Bol ts , Ring Gear . . . . . . . . . . . .108 N·m (80 ft. lbs.)Screw, ABS Sens or . . . . . . . . . . .8 N·m (70 in. lbs.)Screw, Pinion Gear Mate

Shaf t Lock . . . . . . . . . . . . . .17.6 N·m (13 ft. lbs.)Nu t s , Brake Back ing P la t e . . . .61 N·m (45 ft. lbs.)Nu t , P in ion

Gear—Minimum * . . . . . . .298 N·m (220 ft. lbs.)Nu t , P in ion

Gear—Maximum * . . . . . . .380 N·m (280 ft. lbs.)

NOTE: *—Refer to Pinion Gear Removal and Instal-

lation procedures for proper pinion nut tighteninginstructions. Do not exceed 380 N·m (280 ft. lbs.)during collapsible spacer crushing procedure.

SPECIAL TOOLS

MODEL 44 AXLE

Puller Set—C-293-PA

Adapter—C-293-42

Extension—C-293-3

Remover—C-452

Holder—C-3281




Installer—C-3718

Handle—C-4171

Remover—C-4307

Installer—C-4308

Installer—C-4340

Pilot—C-3288

Dial Indicator—C-3339

Trac-lok Tool Set—C-4487


SPECIAL TOOLS (Continued)



Installer—D-163

Installer—D-129

Remover—D-103

Spreader—W-129-B

Remover—6310

Installer—6436

Installer—6437

Installer—6448





Adapter—6790

Pinion Depth Set—6955

Fig. 78 Adapter Set—6956

Holder—6958

Holder—6963-A

Remover—7794-A



Documents

Differential and Driveline96zjs_3