Dodge Dakota (R1). Manual — part 202
Condition
Possible Causes
Correction
Gear Teeth Broke
1. Overloading.
1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation.
2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement.
3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise
1. Insufficient lubricant.
1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion.
3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings.
5. Adjust pinion bearing pre-load.
6. Loose differential bearings.
6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear.
7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly.
9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the skid plate, if equipped.
(3) Remove skid plate support crossmember, if nec-
essary.
(4) Remove both C/V driveshafts.
(5) Mark the propeller shaft, transfer case, and
pinion companion flange for installation reference.
(6) Remove the front propeller shaft.
(7) Remove the axle vent tube.
(8) Use an adjustable and movable jack to support
the differential housing.
(9) Remove bolts holding the axle to the engine
mounts (Fig. 3).
(10) Remove bolts holding the axle to the pinion
nose bracket (Fig. 4).
(11) Lower the jack and housing.
(12) Remove the axle from vehicle.
INSTALLATION
(1) Raise the axle into position. Loosely install the
bolts and nuts to hold the axle to the engine mounts
and pinion nose bracket.
(2) Tighten all the bolts finger-tight, then tighten
all bolts to 95 N·m (70 ft. lbs.).
(3) Install the axle vent tube.
(4) Align the reference marks on the propeller
shaft, transfer case, and pinion companion flange.
(5) Install propeller shaft.
(6) Install the C/V driveshafts.
(7) Install the skid plate support crossmember, if
necessary.
(8) Install the skid plate, if necessary.
(9) Check differential lubricant level and add
lubricant, if necessary.
(10) Remove the supports and lower the vehicle.
3 - 26
FRONT AXLE - C205F
AN
FRONT AXLE - C205F (Continued)
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets
only. The identifying numbers for the ring gear and
pinion are painted onto the pinion gear shaft and the
side of the ring gear. A plus (+) number, minus (–)
number or zero (0) along with the gear set sequence
number (01 to 99) is on each gear. This first number
is the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
marked with a (0). The next two numbers are the
sequence number of the gear set. The standard set-
ting from the center line of the ring gear to the back
face of the pinion is 99.690 mm (3.925 in.). The stan-
dard depth provides the best teeth contact pattern.
Refer to Backlash and Contact Pattern in this section
for additional information.
Compensation
for
pinion
depth
variance
is
achieved with select shims. The shims are placed
between the rear pinion bearing cone and the pinion
gear head. (Fig. 5).
If a new gear set is being installed, note the depth
variance marked on both the original and replace-
ment pinion. Add or subtract the thickness of the
original 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 painted number on the shaft of the drive
pinion (–1, –2, 0, +1, +2, etc.). The numbers repre-
sent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shim(s). If the num-
ber is positive, 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.
Fig. 3 Axle Mounting
1 - LEFT ENGINE MOUNT
2 - RIGHT ENGINE MOUNT
3 - FRONT AXLE
Fig. 4 Pinion Nose Mounting
1 - PINION NOSE BRACKET
2 - FRONT AXLE
Fig. 5 Adjustment Shim
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
5 - COLLAPSIBLE SPACER
AN
FRONT AXLE - C205F
3 - 27
FRONT AXLE - C205F (Continued)
PINION GEAR DEPTH VARIANCE
Original
Pinion
Gear
Depth
Variance
Replacement Pinion Gear Depth Variance
−4
−3
−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
−0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
−0.001
−0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
−0.001
−0.002
−0.003
0
+0.004
+0.003
+0.002
+0.001
0
−0.001
−0.002
−0.003
−0.004
−1
+0.003
+0.002
+0.001
0
−0.001
−0.002
−0.003
−0.004
−0.005
−2
+0.002
+0.001
0
−0.001
−0.002
−0.003
−0.004
−0.005
−0.006
−3
+0.001
0
−0.001
−0.002
−0.003
−0.004
−0.005
−0.006
−0.007
−4
0
−0.001
−0.002
−0.003
−0.004
−0.005
−0.006
−0.007
−0.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 8177,
Arbor Discs 8541 and Dial Indicator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8177 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through the
pinion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone 6740 onto
the screw hand tight (Fig. 6).
(4) Place Arbor Discs 8541 on Arbor D-115-3 in
position 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.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in the housing so dial probe and scooter block are
flush against the surface of the pinion height block.
Hold scooter block in place and zero the dial indica-
tor. Tighten dial indicator face lock screw.
(7) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
Observe how many revolutions counterclockwise the
dial pointer travels (approximately 0.125 in.) to the
out-stop of the dial indicator.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 9). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
Fig. 6 Pinion Gear Depth Gauge Tools
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
3 - 28
FRONT AXLE - C205F
AN
FRONT AXLE - C205F (Continued)
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
marked on the shaft of the pinion gear using the
opposite sign on the variance number. For example, if
the depth variance is –2, add +0.002 in. to the dial
indicator reading.
(10) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cup and the housing. The proper shim thick-
ness can be determined using slip-fit Dummy Bear-
ings 8398 in place of the differential side bearings
and a Dial Indicator C-3339. Before proceeding with
the differential bearing preload and gear backlash
measurements, measure the pinion gear depth and
prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading, starting point shim thicknesses, and the
preload specification added together. The gear back-
lash 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 side of the differential (Fig.
10).
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.
Fig. 7 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 8 Gauge Tools In
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
AN
FRONT AXLE - C205F
3 - 29
FRONT AXLE - C205F (Continued)
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