Differential Carrier Bearing Preload Adjustment 10.5 Inch Axle

Tools Required

J 24429 Side Bearing Backlash Spanner

Important: The rotating torque of the drive pinion must be within specifications before the pinion gear bearing retain or the differential case assembly can be installed.

1. Install the pinion gear bearing retainer assembly. Refer to Drive Pinion Housing and/or Seal Replacement .

Important: The differential side bearing preload is adjusted by the 2 adjusting nuts in the bearing bore. The bore and the bearing cap provide the mating threads for the bearing nut.

The differential must be initially prelubricated in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set.
2. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement .
3. Install the differential side bearing adjuster nuts.

Important: Before installation of the differential case assembly, ensure that the side bearing surfaces in the carrier are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used.

If the differential case assembly cannot be installed, turn the differential side bearing adjuster nuts into the axle housing until the differential case assembly until the proper clearance can be obtained.
4. Install the differential case assembly.
5. Install the differential bearing caps.
6. Install the differential bearing cap bolts.

Important: In the following service procedure, DO NOT torque the bearing cap bolts, only finger tighten them.

7. Install the bearing cap bolts.

Important: DO NOT FORCE the ring gear into contact with the drive pinion.

8. Slide the differential case assembly towards the right side axle housing until the ring gear contact the pinion (this is the zero backlash point).

Important: If the zero backlash cannot be obtained, turn the right side differential bearing adjuster nut in towards the axle housing until the ring gear fully contacts the pinion to obtain the zero backlash.

9. Check for zero backlash.
10. While holding the ring gear against the pinion, turn the left differential bearing adjuster nut out from the axle housing using the J 24429 until it contacts the differential side bearing.
11. Turn the right differential bearing adjuster nut out from the axle housing using the J 24429 until it contacts the differential side bearing.
12. Back off the left adjusting nut approximately 2 slots using the J 24429 in order to obtain the initial backlash adjustment.

Important: In the following service procedure, DO NOT torque the adjuster nut lock bolt.

13. Install the left adjuster nut lock and the adjuster nut lock bolt.
14. Using the J 24429 , tighten the right differential bearing adjuster nut until the differential case is in contact with the left differential adjuster nut.
15. Rotate the pinion several times in order to seat the bearings.
16. Loosen the right differential bearing adjuster nut using the J 24429 until the nut is free from the differential side bearing.
17. Tighten the right differential bearing adjuster nut using the J 24429 until the differential bearing adjuster nut contacts the bearing.
18. Once the right differential bearing adjuster contacts the differential bearing, tighten the differential bearing adjuster nut using the J 24429 the following additional amounts:

Tighten

•	For used bearings, tighten the differential bearing adjuster nut an additional 2 slots.

•	For new bearings, tighten the differential bearing adjuster nut an additional 3 slots.

19. Install the right differential bearing adjuster nut lock.

Important: In the following service procedures, DO NOT torque the bolt at this time

20. Install the right differential bearing adjuster nut lock bolt.

Notice: Refer to Fastener Notice in the Preface section.

21. Tighten the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 185 N·m (136 lb ft).

22. Tighten differential bearing adjuster nut lock bolts.

Tighten
Tighten the differential bearing adjuster nut lock bolts to 27 N·m (20 lb ft).

23. Measure the ring gear to pinion backlash and adjust, if necessary. Refer to Backlash Adjustment .

Differential Carrier Bearing Preload Adjustment 9.75 Inch Axle

Tools Required

Measurement and Adjustment Procedure

1. Remove the differential side bearing shims. Refer to Drive Pinion Bearings Replacement .
2. Determine the pinion position shim and the pinion preload shims, if necessary. Refer to Pinion Depth Adjustment .



3. Install the differential side bearing without the side bearing shims by doing the following:

3.1.	In order to protect the differential case, install the J 36597 in the case on the side opposite of the bearing installation.

3.2.	Install the differential side bearing.

3.3.	Install the J 24430 or the J 45900  (2) and the J 8092  (1) over the differential side bearing.

3.4.	Drive the differential side bearing into position using the J 24430 or the J 45900 and the J 8092 .

4. Install the differential assembly into the axle housing.
5. Move the differential assembly to the left until the left differential side bearing is against the left side bearing bore.

Important: Install the bearing caps into the same position from which each was removed.

6. Install the left side bearing cap.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the left side bearing cap bolts.

Tighten
Tighten the bearing cap bolts finger tight. Do not tighten the bolts to specification at this time.

8. While holding the differential assembly against the left side bearing bore, press the right side bearing cup against the right differential side bearing.

Important: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.




9. Using a feeler gage, measure the distance between the right side bearing cup and the right side bearing bore. Use progressively larger feeler gage sizes until a moderate drag is felt. Repeat this step several times while rotating the differential case in order to obtain a consistent reading.

This measurement, measurement a, is the total shim pack thickness for the differential assembly without preload.

Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

10. Remove the left side bearing cap bolts.
11. Remove the left side bearing cap.
12. Install the right side bearing cap.
13. Install the right side bearing cap bolts.

Tighten
Tighten the bearing cap bolts finger tight. Do not tighten the bolts to specification at this time.

14. While holding the differential assembly ring gear against the drive pinion, press the left side bearing cup against the left differential side bearing.

Important: In order to accurately measure the differential side bearing shim thickness, the differential side bearing cup must be evenly seated against the differential side bearing.




15. Using a feeler gage, measure the distance between the left side bearing cup and the left side bearing bore. Use progressively larger feeler gage sizes until a moderate drag is felt. Repeat this step several times while re-positioning the differential case in order to obtain a consistent reading.

This measurement, measurement b, is the left side shim thickness for the differential assembly without preload.

16. In order to determine the right side shim thickness, subtract the left side measurement, measurement b, from the total shim measurement, measurement a.

This measurement is the thickness for the right side shim thickness without preload or setting the initial backlash.

17. Remove the right side bearing cap bolts.
18. Remove the right side bearing cap.
19. Remove the differential assembly.



20. Remove the differential side bearings by performing the following steps:

20.1.

Install the J 45711  (2) and the J 36597  (1) as shown.

20.2.

Remove the differential side bearings using the J 45711 and a hydraulic press.

21. Add 0.25 mm (0.010 in) of shim thickness to the right side shim thickness measurement determined in step 16.

This additional amount will set the differential side bearing preload and the initial backlash.

Important: The number of shims required in order to equal the correct thickness may consist of one or more shims.

22. Install the right side shim thickness onto the differential case.

Measure the shims one at a time. Add the measurements together in order to obtain the total thickness of the right side shim pack.




23. Install the right differential side bearing with the side bearing shim thickness by doing the following:

23.1.

In order to protect the differential case, install the J 8107-3 in the case on the side opposite of the bearing installation.

23.2.

Place the differential side shim thickness on top of the differential case.

23.3.

Place the differential side bearing on top of the differential case.

23.4.

Install the J 24430 or the J 45900  (2) and the J 8092  (1) over the differential side bearing.

23.5.

Drive the differential side bearing into position using the J 24430 or the J 45900 and the J 8092 .

Important: The number of shims required in order to equal the correct thickness may consist of one or more shims.

24. Install the left side bearing shim thickness and differential side bearing using the steps above.
25. Install the differential assembly into the axle housing. Refer to Differential Replacement .
26. Adjust the backlash. Refer to Backlash Adjustment .

The differential side bearing shims are available in the following sizes:

Shim Sizes

Differential Carrier Bearing Preload Adjustment 9.5 Inch Axle

Tools Required

Important: 

•	The drive pinion bearing preload must be within specifications before the differential side bearing preload adjustment can be performed.

•	The differential side bearings must be initially preloaded in order to determine the backlash of the gear set. After the backlash is set, the final bearing preload is set.

Caution: To prevent personal injury and/or component damage, support the differential case when removing the case from the axle housing. If the case is not supported, the differential case could fall and cause personal injury or damage to the differential case.

1. Remove the differential assembly, if necessary.
2. Measure the rotating torque of the drive pinion bearing using an inch-pound torque wrench.

Specification
The rotating torque of the drive pinion should be 1.7-3.4 N·m (15-30 lb in) for new bearings or 1.1-2.3 N·m (10-20 lb in) for used bearings.

3. If the rotating torque of the drive pinion is less than 1.7 N·m (15 lb in) for new bearings or 1.1 N·m (10 lb in) for used bearings, tighten the pinion in small increments until the specified rotating torque is obtained.
4. If the rotating torque of the drive pinion is greater than 3.4 N·m (30 lb in) for new bearings or 2.3 N·m (20 lb in) for used bearings, remove the drive pinion and replace the collapsible spacer and re-install the drive pinion. Refer to Drive Pinion Bearings Replacement .
5. Install the differential assembly, if necessary.
6. Support the differential assembly in order to prevent the differential assembly from falling out of the axle housing.

Important: Do not force the ring gear into contact with the drive pinion.

7. Slide the differential case assembly towards the right side axle housing until the ring gear contacts the drive pinion.

This is the ZERO backlash point.

If the ZERO backlash cannot be obtained, turn the differential bearing adjuster nut into the axle housing using the J 24429 until the ring gear fully contacts the drive pinion to obtain the ZERO backlash.

8. While holding the ring gear against the pinion, turn the differential bearing adjuster nut out from the axle housing using the J 24429 until it contacts the differential side bearing.
9. Turn the adjuster nut out from the axle housing an additional 2 slots using the J 24429 in order to obtain the initial backlash adjustment.
10. Install the adjuster nut lock and the adjuster nut lock bolt.
11. Remove the left side differential bearing cap bolts.
12. Remove the left side differential bearing cap.



13. Install the J 22779 into the left side axle housing between the differential bearing bore and the differential bearing cup.

Important: Over-tightening may spread the axle housing and result in incorrect shim selection.

14. Tighten the knob of the J 22779 until there is moderate drag when the J 22779 is moved.
15. Remove the J 22779 .
16. Measure the J 22779 in 3 locations.
17. Calculate the average of the 3 measurements.

The resulting value is the shim thickness required in order to set the initial backlash of the differential assembly.

18. Select a service shim of approximately the same thickness to install into the axle housing.

Verify the thickness of the service shim using a micrometer.

19. Install the service shim into the axle housing between the differential bearing bore and the differential bearing cup.
20. Install the left side differential bearing cap.
21. Install the left side differential bearing cap bolts.

Tighten the differential bearing cap bolts finger-tight. Do not torque the bolts at this time.

22. Remove the differential bearing adjuster nut lock bolt.
23. Remove the differential bearing adjuster nut lock.
24. Firmly tighten the differential bearing adjuster nut using the J 24429 in order to force the differential case assembly into solid contact with the service shim.
25. Rotate the pinion several times in order to seat the bearings.
26. Loosen the differential bearing adjuster nut using the J 24429 until the nut is free from the differential side bearing.
27. Tighten the differential bearing adjuster nut using the J 24429 until the differential bearing adjuster nut contacts the bearing.
28. Once the right differential bearing adjuster contacts the differential bearing, tighten the differential bearing adjuster nut using the J 24429 the following additional amounts:

Tighten

•	For new bearings, tighten the differential bearing adjuster nut an additional 3 slots.

•	For used bearings, tighten the differential bearing adjuster nut an additional 2 slots.

29. Install the right differential bearing adjuster nut lock.
30. Install the right differential bearing adjuster nut lock bolt.

Do not torque the bolt at this time.

Notice: Refer to Fastener Notice in the Preface section.

31. Tighten the bearing cap bolts.

Tighten
Tighten the bearing cap bolts to 85 N·m (63 lb ft).

32. Tighten the differential bearing adjuster nut lock bolt.

Tighten
Tighten the differential bearing adjuster nut lock bolt to 26 N·m(19 lb ft).

33. Measure the drive pinion and differential case side bearing preload using an inch-pound torque wrench.

Rotate the pinion several times to ensure the bearings have seated.

Specification
The rotating torque of the drive pinion and differential case bearings should be 3.9-6.2 N·m (30-55 lb in) for new bearings or 2.8-5.1 N·m (25-45 lb in) for used bearings.

Record the measurement.

34. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and differential case bearing preload, measured in Step 33.

Multiply the value obtained by the axle ratio.

Specification
The differential case side bearing preload should be 1.7-4.0 N·m (15-35 lb in).

35. If the differential case side bearing preload is not within specifications, increase or decrease the shim thickness as necessary in order to increase/decrease the side bearing preload.
36. Once the differential side bearing preload is correct, measure the drive pinion to differential assembly backlash and adjust, if necessary. Refer to Backlash Adjustment .

Differential side bearing shims are available in the following sizes:

Shim Sizes

Differential Carrier Bearing Preload Adjustment 8.6 Inch Axle

Wedge Method

Tools Required

Important: 

•	In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally.

•	Measure the service shims and the spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack.

•	Do not use or reuse the original cast iron production shims. Use service shims and spacers instead.

1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Record the measurement.

Specification
The rotating torque of the drive pinion should be 1.7-3.4 N·m (15-30 lb in) for new bearings or 1.1-2.3 N·m (10-20 lb in) for used bearings.

3. If the rotating torque for the drive pinion bearings is not within specifications, adjust as necessary. Refer to Drive Pinion and Ring Gear Replacement .

Important: Before installation of the differential assembly, ensure that the differential side bearing surfaces in the axle housing are clean and free of burrs. If the original differential side bearings are to be reused, the original differential side bearing cups must also be used.

4. Install the differential assembly with the differential side bearings and differential side bearing cups into the axle housing.
5. Insert one 4.318 mm (0.170 in) thick service spacer into the left side of the axle housing.
6. Side the differential assembly towards the service spacer in order to hold the spacer in place.
7. Install the J 22779 into the right side of the axle housing.

The J 22779 must be installed between the service spacer and the differential side bearing cup.

Important: Over-tightening of the J 22779 may spread the housing and result in incorrect shim selection.

8. Tighten the knob on the J 22779 until there is moderate drag when the J 22779 is moved.
9. Remove the J 22779 .
10. Remove the service spacer.
11. Using a micrometer, measure the thickness of the service spacer. Record the measurement.
12. Using a micrometer, measure the thickness of the J 22779 in 3 locations. Calculate the average of the 3 measurements. Record the measurement.
13. Add the thickness of the service spacer, measured in step 11 to the average thickness of the J 22779 , measured in step 12. The resulting value is the total service shim thickness without preload for the axle.
14. Insert one BENT 1.016 mm (0.040 in) service shim between the right side differential side bearing cup and the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
15. Install the J 22779 into the left side of the axle housing. The J 22779 must be installed between the service spacer and the differential side bearing cup.
16. While rotating the ring gear back and forth, tighten the knob on the J 22779 until there is approximately 0.025-0.051 mm (0.001-0.002 in) of backlash between the ring gear and the drive pinion.
17. Once the correct amount of backlash is obtained, remove the J 22779 .
18. Remove the differential assembly with the differential side bearings and the differential side bearing cups.
19. Remove the BENT service shim.
20. Using a micrometer, measure the thickness of the J 22779 in 3 locations. Calculate the average of the 3 measurements. This value is the left side service shim thickness without preload.
21. In order to determine the right side service shim thickness, subtract the service shim thickness for the left side of the axle, calculated in step 20, from the total service shim thickness, calculated in step 13. This value is the service shim thickness for the right side of the axle without preload.
22. In order to preload of the differential side bearings and set the backlash to approximately 0.127-0.223 mm (0.005-0.009 in), take the value determined in step 21 and add 0.203 mm (0.008 in) service shim thickness to this amount.
23. Assemble the left side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of service shims equaling the thickness determined in step 20. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
24. Assemble the right side shim pack using one 4.318 mm (0.170 in) service spacer and the appropriate amount of service shims equaling the thickness determined in step 22. Measure the service spacer and the service shims separately. Add the measurements together in order to determine the total shim pack thickness.
25. Install the differential assembly with the differential side bearings and the differential side bearing cups.
26. Install the left side service spacer and service shim into the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
27. Install the right side service spacer between the axle housing and the differential side bearing cup.
28. Install the right side service shim into the axle housing using the J 25588 , if necessary. The service shim must be installed between the service spacer and the differential side bearing cup.

Notice: Refer to Fastener Notice in the Preface section.

29. Install the differential bearing caps and the bolts.

Tighten
Tighten the differential bearing cap bolts to 75 N·m (55 lb ft).

30. Rotate the pinion several times to ensure the drive pinion and differential side bearings have seated.
31. Measure the rotating torque of the drive pinion and differential side bearings using an inch-pound torque wrench. Record the measurement.

Specification
0.57-1.13 N·m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.

32. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in step 2, from the drive pinion and differential case bearing preload, measured in step 31. Multiply the value obtained by the axle ratio.

Specification
The differential side bearing preload should be 1.7-4.0 N·m (15-35 lb in).

33. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
34. Once the differential side bearing preload is correct, measure the backlash and adjust, if necessary. Refer to Backlash Adjustment .
35. Once the differential side bearing preload and backlash is correct, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection .

Shim Method

Tools Required

J 25588 Side Bearing Shim Installer

Important: 

•	In order to maintain the original backlash, adjust the differential case side bearing preload by changing the thickness of the left and the right side shim packs equally.

•	Measure the service shims and the service spacers one at a time. Add the measurements together in order to obtain the total thickness of the left or the right side shim pack.

•	Do not use or reuse the original cast iron production shims. Use service shims and service spacers instead.

1. Install the drive pinion, if necessary. Refer to Drive Pinion and Ring Gear Replacement .
2. Measure the rotating torque of the drive pinion using an inch-pound torque wrench. Record the measurement.

Specification
The rotating torque for the drive pinion bearings should be 1.7-3.4 N·m (15-30 lb in) for new bearings or 1.1-2.3 N·m (10-20 lb in) for used bearings.

3. If the rotating torque for the drive pinion bearings is not within specifications, adjust as necessary. Refer to Drive Pinion and Ring Gear Replacement .

Important: Before installation of the case assembly, ensure that the side bearing surfaces in the axle housing are clean and free of burrs. If the original bearings are to be reused, the original bearing cups must also be used.

4. Install the differential assembly with the differential side bearings and bearing cups into the axle housing.
5. Insert one BENT 1.016 mm (0.040 in) thick service shim into the right side axle housing. Side the differential assembly towards the bent service shim in order to hold the shim in place.
6. While holding the differential assembly against the bent service shim, install one 4.318 mm (0.170 in) thick service spacer into the left side axle housing.
7. Move the differential assembly to the right until the ring gear contacts the drive pinion. Once the ring gear contacts the drive pinion, continue to move the ring gear towards the drive pinion to until all backlash is removed.
8. While holding the ring gear against the drive pinion, insert progressively larger service shims between the service spacer and the differential side bearing cup until a moderate resistance can be felt.
9. Once the largest service shim has been determined, measure the thickness of the shim using a micrometer. Measure the service shim in 3 locations. Calculate the average of the 3 measurements. Use the average as the thickness for the shim. Record the measurement.
10. Install the service shim that was just measured back into the left side of the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
11. Remove the BENT shim from the right side of the axle housing.
12. Insert one 4.318 mm (0.170 in) thick service spacer into the right side axle housing.
13. Move the differential assembly towards the left side of the axle housing. While holding the differential assembly against the left side shim pack, insert progressively larger service shims between the service spacer and the differential side bearing cup until a moderate resistance can be felt.
14. Once the largest service shim has been determined, measure the thickness of the shim using a micrometer. Verify the thickness of the service shim. Measure the service shim in 3 locations. Calculate the average of the 3 measurements. Use the average as the thickness for the shim. Record the measurement.
15. In order to preload the differential side bearing and set the initial backlash to approximately 0.127 mm (0.005 in), adjust the thickness of left and right side shims by doing the following:

15.1.

Subtract 0.152 mm (0.006 in) from the measurement recorded for the left side shim in step 9. Record the measurement.

15.2.

Add 0.356 mm (0.014 in) to the measurement recorded for the right side shim in step 14.

16. Select the correct service shim thickness for each side corresponding to the measurements determined above. Using a micrometer, verify the thickness of the service shim. Measure the service shim in 3 locations. Calculate the average of the 3 measurements. Use the average as the thickness for the shim.
17. Install the left side service shim into the axle housing. The service shim must be installed between the service spacer and the differential side bearing cup.
18. Move the differential assembly towards the left side of the axle housing.
19. Install the right side service shim into the axle housing using the J 25588 , if necessary. The service shim must be installed between the service spacer and the differential side bearing cup.

Notice: Refer to Fastener Notice in the Preface section.

20. Install the differential bearing caps and bolts.

Tighten
Tighten the differential bearing cap bolts to 75 N·m (55 lb ft).

21. Rotate the pinion several times to ensure the bearings have seated.
22. Measure the rotating torque of drive pinion and differential case side bearings using an inch-pound torque wrench.

Specification
0.57-1.13 N·m (5-10 lb in) greater than the rotating torque of the drive pinion measured earlier.

23. Calculate the differential side bearing preload by subtracting the drive pinion preload, measured in Step 2, from the drive pinion and the differential case bearing preload, measured in Step 23. Multiply the value obtained by the axle ratio.

Specification
The differential side bearing preload should be 1.7-4.0 N·m (15-35 lb in).

24. If the differential side bearing preload is not within specifications, add or subtract shim thickness equally from each shim pack as necessary in order to increase/decrease the side bearing preload.
25. Once the differential side bearing preload is within specifications, measure the backlash between the ring gear and the drive pinion and adjust, if necessary. Refer to Backlash Adjustment .
26. Once backlash and differential side bearing preload is within specifications, perform a gear tooth contact pattern check in order to ensure proper alignment between the ring and pinion gears. Refer to Gear Tooth Contact Pattern Inspection .