Dodge Dakota (R1). Manual — part 203
(3) Install Dummy Bearings 8398 on differential
case.
(4) Install differential case in the housing.
(5) Insert Dummy Shims 8107 (0.118 in. (3.0 mm))
starting point shims between both dummy bearings
and the housing (Fig. 11).
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow hammer to seat the differ-
ential dummy bearings to each side of the differential
housing (Fig. 12) and (Fig. 13).
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 14).
(9) Attach Dial Indicator C-3339 to post and posi-
tion dial indicator plunger on a flat surface on a ring
gear bolt head (Fig. 14).
(10) Push firmly and hold differential case to pin-
ion side of axle housing (Fig. 15) and zero dial indi-
cator.
(11) Push firmly and hold differential case to the
ring gear side and record dial indicator reading (Fig.
16).
(12) Add the dial indicator reading to the starting
point shim thicknesses to determine the total shim
thickness necessary to achieve zero differential end
play.
(13) Add 0.2 mm (0.008 in) to the zero end play
total. This new total represents the thickness of
shims necessary to compress, or preload the new
bearings when the differential is installed.
(14) Rotate dial indicator out of the way on pilot
stud.
(15) Remove differential case, dummy bearings,
and starting point shims from the housing.
(16) Install the pinion in the axle housing. Install
the companion flange and establish the correct pinion
rotating torque.
(17) Install differential case and Dummy Bearings
in axle housing with a single dummy shim on the
ring gear side of the axle and tighten retaining cap
bolts.
Fig. 10 Adjustment Shim
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
5 - COLLAPSIBLE SPACER
Fig. 11 Shim Starting Point
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 12 Seat Pinion Side Dummy Bearing
1 - DEAD-BLOW HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
3 - 30
FRONT AXLE - C205F
AN
FRONT AXLE - C205F (Continued)
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 14).
(19) Push and hold differential case toward pinion.
(20) Zero dial indicator face to pointer.
(21) Push and hold differential case to ring gear
side of the housing.
(22) Record dial indicator reading.
(23) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. Add the resulting measure-
ment to the thickness of the single starting point
shim. This total is the thickness of shim required to
achieve proper backlash.
(24) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
axle housing.
(25) Rotate dial indicator out of the way on pilot
stud.
Fig. 13 Seat Ring Gear Side Dummy
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
Fig. 14 Differential Side play
1 - DIFFERENTIAL CASE
2 - DIFFERENTAIL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 Zero Dial Indicator
1 - CASE TO PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - DIAL INDICATOR
Fig. 16 Read Dial Indicator
1 - DIAL INDICATOR
2 - CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
AN
FRONT AXLE - C205F
3 - 31
FRONT AXLE - C205F (Continued)
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates
8142-A on the housing and spread open enough to
receive differential case.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 17).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the differential housing to the
other (Fig. 18).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the hous-
ing. It will also show if the ring gear backlash has
been adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact
patterns.
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on a ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
19)and adjust pinion depth and gear backlash as nec-
essary.
Fig. 17 Ring Gear Backlash
1 - DIAL INDICATOR
Fig. 18 Backlash Shim Adjustment
3 - 32
FRONT AXLE - C205F
AN
FRONT AXLE - C205F (Continued)
Fig. 19 Gear Tooth Contact Patterns
AN
FRONT AXLE - C205F
3 - 33
FRONT AXLE - C205F (Continued)
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