Dodge Dakota (R1). Manual — part 224
REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Secure brake drums to the axle shaft.
(6) Remove the RWAL sensor from the differential
housing. Refer to 5 Brakes for procedures.
(7) Disconnect the brake hose at the axle junction
block. Do not disconnect the brake hydraulic lines at
the wheel cylinders. Refer to 5 Brakes for procedures.
(8) Remove parking brake cables and cable brackets.
(9) Disconnect the vent hose from the axle shaft tube.
(10) Mark propeller shaft and companion flange
for installation reference.
(11) Remove propeller shaft.
(12) Remove shock absorbers from axle.
(13) Remove spring clamps and spring brackets.
Refer to 2 Suspension for procedures.
(14) Separate the axle from the vehicle.
INSTALLATION
(1) Raise the axle with lifting device and align to
leaf spring centering bolts.
(2) Install spring clamps and spring brackets.
Refer to Suspension for procedures.
(3) Install shock absorbers.
(4) Install RWAL sensor to the differential hous-
ing. Refer to Brakes for procedures.
(5) Install parking brake cables, cable brackets
and brake drums. Refer to Brakes for procedures.
(6) Connect brake hose to the axle junction block.
Refer to Brakes for procedures.
(7) Install axle vent hose.
(8) Install propeller shaft with reference marks
aligned.
(9) Install the wheels and tires.
(10) Add gear lubricant if necessary. Refer to
Lubricant for lubricant requirements.
(11) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENT
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
4). A plus (+) number, minus (–) number or zero (0) is
etched into the face of the pinion gear. This number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard setting from the cen-
ter line of the ring gear to the back face of the pinion
is 109.52 mm (4.312 in.). The standard depth pro-
vides the best teeth contact pattern. Refer to Back-
lash and Contact Pattern Analysis Paragraph in this
section for additional information.
Compensation
for
pinion
depth
variance
is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 5).
If a new gear set is being installed, note the depth
variance etched into both the original and replacement
pinion gear. Add or subtract the thickness of the origi-
nal depth shims to compensate for the difference in the
depth variances. Refer to the Depth Variance charts.
Note where Old and New Pinion Marking columns
intersect.
Intersecting
figure
represents
plus
or
minus amount needed.
Note the etched number on the face of the drive pin-
ion gear (–1, –2, 0, +1, +2, etc.). The numbers represent
thousands of an inch deviation from the standard. If the
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 Adjustment Shim Locations
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
3a - 6
REAR AXLE - 216RBI
R1
REAR AXLE - 216RBI (Continued)
number is negative, add that value to the required
thickness of the depth shim(s). If the number is posi-
tive, subtract that value from the thickness of the depth
shim(s). If the number is 0 no change is necessary. Refer
to the Pinion Gear Depth Variance Chart.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
2
4
2
3
2
2
2
1
0
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
0
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
1
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
2
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
3
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
4
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
0.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in the housing. Take measure-
ments with a Pinion Gauge Set 6775, Dummy
Bearing Set 6676 and Dial Indicator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8144 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone 6740
hand tight.
Fig. 6 Pinion Gear Depth Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 7 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
R1
REAR AXLE - 216RBI
3a - 7
REAR AXLE - 216RBI (Continued)
(4) Place Arbor Disc 6927 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8). Install
differential bearing caps on Arbor Discs and tighten cap
bolts. Refer to the Torque Specifications in this section.
NOTE: Arbor Discs 6927 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till the dial indicator probe crests the
arbor, then record the highest reading.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 4) using
the opposite sign on the variance number. For exam-
ple, if the depth variance is –2, add +0.002 in. to the
dial indicator reading.
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD
Differential side bearing preload and gear backlash is
achieved by selective shims inserted between the bear-
ing cup and the housing. The proper shim thickness can
be determined using slip-fit Dummy Bearings 6929-A in
place of the differential side bearings and a Dial Indica-
tor C-3339. Before proceeding with the differential bear-
ing preload and gear backlash measurements, measure
the pinion gear depth and prepare the pinion gear for
installation. Establishing proper pinion gear depth is
essential to establishing gear backlash and tooth con-
tact patterns. After the overall shim thickness to take
up differential side play is measured, the pinion gear is
installed and the gear backlash shim thickness is mea-
sured. The overall shim thickness is the total of the dial
indicator reading, starting point shim thickness and the
preload specification added together. The gear backlash
measurement determines the thickness of the shim used
on the ring gear side of the differential case. Subtract
the gear backlash shim thickness from the total overall
shim thickness and select that amount for the pinion
gear side of the differential (Fig. 10).
Fig. 8 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 Adjustment Shim
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - RING GEAR
4 - DIFFERNTIAL BEARING SHIM
5 - COLLAPSIBLE SPACER
3a - 8
REAR AXLE - 216RBI
R1
REAR AXLE - 216RBI (Continued)
PRELOAD SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove side bearings from differential case.
(2) Install ring gear, if necessary on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings 6929-A on differential
case.
(4) Install differential case in the housing.
(5) Insert Dummy Shims 8107 3.0 mm (0.118 in.)
starting point shims between the dummy bearing
and the housing (Fig. 11).
(6) Install bearing caps in their correct positions
and snug the bolts.
(7) Using a dead-blow hammer to seat the differ-
ential dummy bearings to each side of the housing
(Fig. 12) and (Fig. 13).
Fig. 11 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
Fig. 13 Seat Ring Gear Side Dummy Bearing
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
R1
REAR AXLE - 216RBI
3a - 9
REAR AXLE - 216RBI (Continued)
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