Special Tools
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- J-34672 Depth Micrometer
- J-34673 Flat Gauge Bar
- J-8001 Dial Indicator Set
The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced:
- The inner axle shaft
- The inner axle shaft housing
- The clutch shaft
- The differential carrier case
- The ring and pinion gears
- The differential assembly
- The differential bearings
- The carrier connector
Front drive axle clutch shims are available in the following sizes:
| 8.25 Inch Axle | 9.25 Inch Axle |
|---|---|
| 1.27 mm (0.05 in) | 1.30 mm (0.05 in) |
| 1.52 mm (0.06 in) | 1.52 mm (0.06 in) |
| 1.78 mm (0.07 in) | 1.80 mm (0.07 in) |
| 2.03 mm (0.08 in) | 2.03 mm (0.08 in) |
| 2.29 mm (0.09 in) | 2.30 mm (0.09 in) |
| 2.54 mm (0.10 in) | 2.54 mm (0.10 in) |
| 2.70 mm (0.11 in) | 2.80 mm (0.11 in) |
| 3.05 mm (0.12 in) | 3.05 mm (0.12 in) |
| 3.30 mm (0.13 in) | 3.30 mm (0.13 in) |
| 3.56 mm (0.14 in) | 3.55 mm (0.14 in) |
| 3.81 mm (0.15 in) | 3.80 mm (0.15 in) |
| - | 4.05 mm (0.16 in) |
| - | 4.30 mm (0.17 in) |
| - | 4.55 mm (0.18 in) |
| - | 4.80 mm (0.19 in) |
- Install the inner axle bearing and the inner axle seal, if necessary. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (8.6/ 9.25 Inch Axle) .
- Install the following components into the inner axle shaft housing:
- Install the inner axle shaft (1) into the inner axle shaft housing (4).
- Install the thrust washer (with tabs) (5).
Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing.
- Install the thrust washer (without tabs) (6).
- Install the retaining ring (7) into the inner axle shaft (1).
- Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing.
- Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go.
- Install the J-34673 flat gauge bar (1) and the J-34672 depth micrometer (2) onto the inner shaft housing as shown.
- Using the J-34672 depth micrometer, measure the distance from the edge of the inner axle shaft to the surface of the J-34673 flat gauge bar. Ensure the base of the J-34672 depth micrometer is flat against the inner axle shaft.
- Using the J-34672 depth micrometer, measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft.
- Subtract the measurement obtained in step 6 from the measurement obtained in step 7.
This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J-34673 flat gauge bar.
- Using a micrometer, measure the thickness of the J-34673 flat gauge bar.
- Subtract the thickness of the J-34673
flat gauge bar, measured in step 9, from the measurement determined in step 8.
This is the shim thickness for the front axle without having any axle shaft endplay.
- The correct shim size will be one size smaller than the figure obtained in the previous step.
Note the following examples:
- If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim.
- If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim.
NOTE:
In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring.
Fig 3: Measuring Differential Carrier Housing Machined Surface To Front Drive Axle Clutch Shaft Outer Surface