Pinion Depth Adjustment (9.5 Inch Axle)

Special Tools

• GE-8001  Dial Indicator Set
• DT-21777-B  Side Bearing Disc Set
• J-45108  Gauge Plate

Equivalent regional tools:Special Tools 

NOTE:

Make sure all of the tools, the differential side bearing bores, and the pinion bearing cups are clean before proceeding.

1. Using the proper axle lubricant, lubricant the differential pinion bearings. Fluid and Lubricant Recommendations
2. Install the differential pinion bearings into the axle housing.

3. Install the J-21777-8  (1), the J-21777-43  (2), the J-21777-42  (3), and the J-45108  Gauge Plate (4) into the axle housing.

4. Hold the J-21777-43  (2) stationary while turning the torque wrench.
NOTE:

Rotate the assembly several times in both directions in order to seat the pinion bearings.

5. Using an inch pound torque wrench and the J-21777-43  (2), tighten the nut until a rotating torque of 1.7 N.m (15 lb in) is obtained.
6. If the torque is less than 1.7 N.m (15 lb in), tighten the nut until a rotating torque of 1.7 - 2.3 N.m (15 - 20 lb in) is obtained.

7. Assemble and install the J-21777-86  (1 and 2) to the J-21777-1  (3) into the differential carrier bores.

8. Install the bearing caps.
CAUTION:

Refer to Fastener Caution .

9. Install the bearing cap bolts and tighten to:
   1. First Pass 60 N.m (44 lb ft)
   2. Final Pass 30 degrees
NOTE:

The J-21777-1  (3) must rotate back and forth freely within the discs. If the J-21777-1  (3) does not rotate freely, disassemble the components, inspect for proper seating and/or mis-aligned components and re-assemble.

10. Rotate the J-21777-1  (3) within the J-21777-86  (1, 2).
11. Adjust the arbor of the J-21777-1  (3) to the gauge block setting of the J-45108  Gauge Plate.
12. Install the GE-8001  Dial Indicator Set to the J-21777-1  as follows:
    1. Loosely clamp the GE-8001  Dial Indicator Set onto the stem on the J-21777-1  .
    2. Place the contact pad of the GE-8001  Dial Indicator Set onto the mounting post of the J-21777-1  .
    3. With the contact pad of the GE-8001  Dial Indicator Set touching the mounting post of the J-21777-1  , loosen the lock nut on the GE-8001  Dial Indicator Set and push down on the GE-8001  Dial Indicator Set until the needle the GE-8001  Dial Indicator Set has turned 3/4 of a turn clockwise.
    4. Tighten the clamp on the GE-8001  Dial Indicator Set finger tight.
NOTE:

The deflection is the point where the needle changes direction.

13. Move the plunger of the J-21777-1  back and forth until the needle of the GE-8001  Dial Indicator Set indicates the greatest deflection.

14. At the greatest point of deflection, move the housing of the GE-8001  Dial Indicator Set until the needle indicates zero.

15. Move the plunger of the J-21777-1  (3) back and forth again to verify the zero setting. Adjust the housing of the GE-8001  Dial Indicator Set as necessary to set the needle to zero.
16. Rotate the plunger of the J-21777-1  (3) away from the J-45108  Gauge Plate (4), until it no longer touches the J-45108  Gauge Plate (4).
17. The value indicated on the GE-8001  Dial Indicator Set is the thickness of the shim needed in order to set the depth of the pinion.
18. Select the shim that indicates the proper thickness. Measure the shim with a micrometer in order to verify that the thickness is correct.
19. Remove the pinion depth setting tools.
20. Remove the pinion bearings.
21. Install the pinion shim between the pinion gear and the inner pinion bearing. Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) , or Differential Drive Pinion Gear Bearing Replacement (9.5 Inch Axle)