1. If the original bevel gear and pinion set is to be used again, measure old shim pack (2) and make a new shim pack the same thickness. If a new bevel gear and pinion set is used, refer to the Pinion Shim Chart for the amount that the original shim pack should be changed. If three or more shims are used, the smaller shims are to be put in the center of the shim pack. 6. Recheck pinion depth. The measured pinion depth must be within 0.03 mm (0.001 in.) of the required pinion depth. 7. After the pinion depth is correct, remove Pinion Depth Gauge and the pinion shaft. Put ring (9) on the pinion shaft and put gear (10) in position in the housing. [NOTE:
Side of gear (10) with recessed hub must be installed next to ring (9)]. Put the pinion shaft in the housing and through gear (10). Install ring (11) on pinion shaft (6). EXAMPLE: If the old pinion has a mark of (+.06) and the new pinion has a mark of (-.08) add 0.14 mm (0.006 in.) shims to the original shim thickness. 2. Install bearing cups (3) and (4) with new shim pack (2) behind bearing cup (3). Install bearing cone (5) on pinion shaft (6). 8. Set pinion bearing preload. See Pinion Bearing Adjustment. 9. Recheck pinion depth. 3. Put the pinion shaft assembly into the housing and install bearing cone (7) and nut (8).
Tighten nut (8) to a torque of 15 to 34 NҐm (11 to 25 lbҐft) while rotating the pinion. 10. After pinion bearing preload and pinion depth are correct, bend a tab on the lockwasher into a slot of nut (8) to lock it in position. 4. Measure the distance from the centerline of the differential bearing bores to the end of the pinion and determine the amount of shims needed behind bearing cup (3). See Pinion Depth Check. 5. Remove bearing cup (3) and add or remove the required shims. Reinstall bearing cup (3).
Power Train Testing And Adjusting 23 PINION SHIM CHART Old Pinion Marking New Pinion Marking +.10 +.08 +.06 +.04 +.02 0 -.02 -.04 -.06 -.08 -.10 +.10 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) +0.12mm (0.005 in.) +0.14mm (0.006 in.) +0.16mm (0.006 in.) +0.18mm (0.007 in.) +0.20mm (0.008 in.) +.08 -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) +0.12mm (0.005 in.) +0.14mm (0.006 in.) +0.16mm (0.006 in.) +0.18mm (0.007 in.) +.06 -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) +0.12mm (0.005 in.) +0.14mm (0.006 in.) +0.16mm (0.006 in.) +.04 -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) +0.12mm (0.005 in.) +0.14mm (0.006 in.) +.02 -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) +0.12mm (0.005 in.) 0 -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) +0.10mm (0.004 in.) -.02 -.0.12mm (0.005 in.) -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) +0.08mm (0.003 in.) -.04 -0.14mm (0.006 in.) -0.12mm (0.005 in.) -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) +0.06mm (0.002 in.) -.06 -0.16mm (0.006 in.) -0.14mm (0.006 in.) -0.12mm (0.005 in.) -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) +0.04mm (0.002 in.) -.08 -0.18mm (0.007 in.) -0.16mm (0.006 in.) -0.14mm (0.006 in.) -0.12mm (0.005 in.) -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0 +0.02mm (0.001 in.) -.10 -0.20mm (0.008 in.) -0.18mm (0.007 in.) -0.16mm (0.006 in.) -0.14mm (0.006 in.) -0.12mm (0.005 in.) -0.10mm (0.004 in.) -0.08mm (0.003 in.) -0.06mm (0.002 in.) -0.04mm (0.002 in.) -0.02mm (0.001 in.) 0