Specifications

41
Assembly and Installation
MAINTENANCE MANUAL
Hazard Alert Messages
Read and observe all Warning and Caution
hazard alert messages in this publication. They
provide information that can help prevent seri-
ouspersonalinjury,damagetocomponents,or
both.
WARNING
Topreventseriouseyeinjury,alwayswearsafe
eye protection when you perform vehicle main-
tenance or service.
Note all warnings and cautions provided by the
press manufacturer to avoid damage to compo-
nentsandseriouspersonalinjury.
Installation
Installing the Drive Pinion, Adjusting
Pinion Depth and Preload Bearings
Therearetwoproceduresforadjustingpinion
depth. The procedure in this manual is to install
the pinion, bearings and calculated shim pack
into the case WITHOUT the helical gear and
two spacers. After you check the tooth contact
patterns to determine the correct pinion posi-
tion, you must disassemble the differential to
install the helical gear and two spacers.
An optional procedure is to install the pinion,
bearings and calculated shim pack into the
case WITH the helical gear and two spacers.
After you check the tooth contact patterns to
determine the correct pinion position, you only
need to disassemble the differential if an ad-
justmentisnecessary.Bothproceduresareac-
ceptable.
Adjustment
Shim Pack Thickness for a New Drive
Pinion
NOTE:
Use this procedure if you’ll install a new
drive pinion and ring gear set or if you have
to adjust the depth of the drive pinion. If the
pinion depth shims are misplaced during dif-
ferential repair, use 0.030 inch (0.76 mm) for
145 Series differential and 0.050 inch (1.27
mm) for 160 Series differential for the initial
pinion position. Figure 5.1.
1. Use a micrometer to measure the thickness
of the shim pack that was removed from the
differential differential. Record the measure-
ment. Figure 5.2
2. Find the pinion cone (PC) variation number
on the drive pinion you’ll replace. Record the
number. Figure 5.3.
• PC+3,PC-3,+3ou-3=0.003”
• PC+.03,PC0.03mm,+0.03mmou-0.03=
0.03 mm.
Figure 5.1
Figure 5.3
Figure 5.2
SHIMS
SPACER
SPACER
OUTER BEARING
CUP
INNER BEAR-
ING CUP
INNER BEARING
CONE
PINION CONE
VARIATION
NUMBER
DRIVE PINON
OUTER BEARING
CONE
HELICAL
DRIVEN
GEAR