Dodge Dakota (R1). Manual — part 225
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 14).
(9) Attach Dial Indicator C-3339 to the pilot stud
and position indicator plunger on a flat surface of the
ring gear bolt head (Fig. 14).
(10) Push differential case to the pinion gear side
of the housing (Fig. 15) and zero dial indicator.
(11) Push 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 thickness to determine total shim thick-
ness to achieve zero differential end play.
(13) Add 0.3 mm (0.012 in.) to the zero end play
total. This new total represents the thickness of
shims to compress or preload the new bearings when
the differential is installed.
(14) Rotate dial indicator out of the way.
(15) Remove differential case, dummy bearings
and starting point shims from the housing.
(16) Install pinion gear in the housing. Install the
yoke and establish the correct pinion rotating torque.
(17) Install differential case and dummy bearings
in the housing (without shims) and tighten retaining
cap bolts.
(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
gear.
(20) Zero dial indicator face to pointer.
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading.
(22) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness of
shim required to achieve proper backlash.
(23) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(24) Rotate dial indicator out of the way on pilot
stud.
Fig. 14 Differential Side play
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 Zero Dial Indicator
1 - FORCE CASE TO PINION SIDE
2 - PILOT STUD
3 - DIAL INDICATOR EXTENSION
4 - DIAL INDICATOR
Fig. 16 Read Dial Indicator
1 - DIAL INDICATOR
2 - FORCE CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
3a - 10
REAR AXLE - 216RBI
R1
REAR AXLE - 216RBI (Continued)
(25) Remove differential case and dummy bearings
from the housing.
(26) Install new side bearing cones and cups on
differential case.
(27) Install spreader W-129-B and adapters from
Set 6987 on differential housing and spread axle
opening enough to receive differential case.
(28) Place side bearing shims into the housing
against the axle tubes.
(29) Install differential case in the housing.
(30) Rotate the differential case several times to
seat the side bearings.
(31) Position the indicator plunger against a ring
gear tooth (Fig. 17).
(32) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(33) Zero dial indicator face to pointer.
(34) 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).
(35) 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 Analysis 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
squeeze 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 necessary.
DIFFERENTIAL BEARING PRELOAD CHECK
The final check on the differential assembly before
installing the axles is torque to rotate pinion and dif-
ferential combined. This will verify the correct differ-
ential bearing preload.
Torque to rotate the differential and pinion should
be the torque to rotate the pinion plus 0.79-1.24 N·m
(7-11 in. lbs.).
Fig. 17 Ring Gear Backlash
1 - DIAL INDICATOR
Fig. 18 Backlash Shim
R1
REAR AXLE - 216RBI
3a - 11
REAR AXLE - 216RBI (Continued)
Fig. 19 Gear Tooth Contact Patterns
3a - 12
REAR AXLE - 216RBI
R1
REAR AXLE - 216RBI (Continued)
SPECIFICATIONS
REAR AXLE - 216RBI
AXLE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Axle Ratio
3.55, 4.10
Differential Bearing Preload
0.1 mm (0.004 in.)
Differential Side Gear Clearance
0.0-0.15 mm (0.0-0.006 in.)
Ring Gear Diameter
216 mm (8.5 in.)
Ring Gear Backlash
0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth
109.52 mm (4.312 in.)
Pinion Bearing Preload - Original Bearings
1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings
2-4.5 N·m (20-40 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Differential Cover Bolts
41
30
-
Bearing Cap Bolts
108
80
-
Pinion Mate Shaft Screw
17.6
13
-
Ring Gear Bolts
108
80
-
Pinion Nut Minimum
298
220
-
Pinion Nut Maximum
380
280
-
R1
REAR AXLE - 216RBI
3a - 13
REAR AXLE - 216RBI (Continued)
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