MGB MGC 1968 74 Repair Manual

Models Covered:

MGB & MGB/GT (1968-74)

MGC & MGC/GT (1969)

DESCRIPTION

Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts can be serviced without removing axle from vehicle. All differential adjustments are performed using shims. No adjustments for axle shaft end play is necessary. A collapsible spacer is used on drive pinion shaft.

AXLE RATIO AND IDENTIFICATION

Only one basic axle design is used on these models. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.

REMOVAL AND INSTALLATION

AXLE SHAFT AND BEARINGS

1) With vehicle raised and supported, rear wheel remove and handbrake released, remove contersunk screws (disc wheels) or nuts (wire wheels) securing brake drum. Top off drum. It may be necessary to loosen brake adjusters if shoes hold drums. Remove cotter pin and unscrew slotted axle shaft nuts and remove hub. Disconnect brake cable and hose.

2) Remove brake backplate, then remove oil seal collar bearing hub cap and oil seal from axle shaft. Remove axle shaft using suitable tool and press bearing from shaft. To install, repack bearing with grease and reverse removal procedure. Use suitable tool to drift axle shaft into position. Lubricate and install new oil seal with lip facing inwards.

PINION FLANGE AND SEAL

1) Raise and support rear of vehicle, remove wheels and brake drums. Drain rear axle. Mark propeller shaft and pinion flange for correct reassembly and disconnect propeller shaft. Using suitable tool, measure and record torque required to rotate pinion. Using tool to prevent pinion rotation, remove flange retaining nut and washer, withdraw pinion flange. Extract and discard oil seal.

2) Grease edge and sealing lip of new oil seal and install seal flush with axle housing. Install pinion flange and washer, and screw on retaining nut gradually until resistance is felt. Rotate pinion to settle bearings and measure torque required to rotate pinion. If reading obtained is less than value obtained during disassembly, tighten nut a VERY small amount, resettle bearings and recheck torque. Repeat this procedure until a reading equal to previous reading, but not less than 4-6 INCH lbs. (4-7 cmkg) is obtained. CAUTION - Preload build up is rapid, tighten nut with care. If a torque reading in excess of 6 INCH lbs. (7 cmkg) is exceeded, axle must be dismantled and a new collapsible spacer installed. Continue reassembly reverse of disassembly procedure.

AXLE ASSEMBLY

1) Rear rear of vehicle and mark propeller shaft and flange for correct reassembly. Disconnect propeller shaft. Remove nuts and washers securing each end of rebound straps to anchor pins on axle and remove straps. Disconnect handbrake at operating levers and remove cable clamp from housing. Remove nut securing brake balance lever to pivot on axle housing. Disconnect shock absorber from rear spring clamp plate.

2) Disconnect brake line and release exhaust pipe from exhaust manifold and supporting brackets, lower exhaust pipe assembly. Remove nut and washer from each spring front anchor pin. Support axle housing and remove rear shackle plates, brackets and rubber bushings. Lower axle support until axle and spring assembly rests on wheels. Remove front anchor pins and roll assembly from beneath vehicle to reinstall, reverse removal procedure.

OVERHAUL

DISASSEMBLY

1) Drain and remove axle from vehicle. Remove axle shafts and hubs. Remove differential cover and mark each differential bearing cap before removal to ensure correct replacement. Remove bolts and bearing caps. Before differential assembly can be removed from axle housing, housing must be stretched with a suitable stretching tool (18G-131 C). Do not stretch housing more than is absolutely necessary or housing may be damaged. Maximum stretch is .012" (.3 mm) or 9 flats of tool 18G-131 C. Pry differential assembly out of housing using care not to damage case or apply leverage on stretcher. Release housing stretcher

2) Bend back locking tabs and remove ring gear bolts and ring gear. Drive out pinion shaft pin and rmeove shaft. Turn differential gears by hand until pinions are opposite operating in differential cage and remove pinions and thrust washers. Remove differential gears and thrust washers, if necessary remove differential inner bearing races using suitable tools.

3) Before removing pinion measure preload; if this is zero, install new pinion bearings. Hold pinion flange and remove pinion nut and washer. Remove flange by tapping with soft hammer. Remove pinion by pressing out, do not drive out. Using suitable tools, remove front and rear bearing outer  races form axle housing. As front race is removed, oil seal will come out with it. Remove rear bearing inner race from pinion.

REASSEMBLY AND ADJUSTMENT

Drive Pinion Depth - 1) Install bearing outer races in axle housing using suitable tools. Using a dummy pinion (18G-191H), install inner race of bearing on dummy and plate in housing without collapsible spacer or oil seal. Install inner race of front bearing. NOTE - A standard pinion head spacer of .208" (5.3 mm) is incorporated in dummy pinion. Install pinion flange and tighten nut gradually until a bearing preload figure of 10-20 INCH lbs. (11-20 cmkg) is obtained.

2) Clean dummy pinion head and position dial indicator foot on pinion head and zero indicator. Move indicator until foot of gauge rests on center of differential bearing bore and route indicator reading. Repeat this procedure on opposite bearing bore and average the two figures. The reading shown on indicator will be amount of correction necessary from standard spacer of .208" (5.3 mm). If indicator reading is negative, reduce spacer thickness by this amount and visa versa.

3) Allowance must also be made for pinion depth marked on pinion head in a rectangular bracket. If marking is positive, reduce washer thickness by equal amount and visa versa. A tolerance of .001" (.03 mm) is allowed in thickness of washer finally installed. Remove dummy pinion.

Pinion Bearing Preload - 1) Install washer of thickness calculated above under pinion head. Install pinion inner bearing race. Insert pinion into case and install collapsible spacer with small diameter towards shoulder of pinion head. Support head of pinion and press outer bearing onto pinion using care not to compress spacer .Grease edge and sealing lip of seal and install seal flush with axle housing. Install flange, washer and nut.

2) Tighten flange nut slowly until spacer starts to collapse. Rotate pinion to settle bearings and check pinion preload. Continue tightening very small amounts between each preload check until specified preload is obtained. CAUTION - Bearing preload is rapid. If preload torque of 24 INCH lbs. (30 cmkg) is exceeded, pinion must be dismantled and a new collapsible spacer is installed.

Side Bearing Preload - 1) Assemble each inner and outer bearing race to differential assembly. Using ring gear setting tools (18G-191, 18G-191 F & 18G-191 J) place differential assembly onto jig and load ring gear assembly (see illustration). Spin unit to settle bearings. Standard measurement of bearing bores is 7.243" (183.98 mm). Any excess machined from bores will be marked A and B on axle casing. The A and B tolerances added to standard measurement will determine overall dimension, see example

EXAMPLE

  Differential case standard....................... 7.243 (183.98 mm)

  PLUS value "A" stamped on case.......... .001" (.025 mm)

  PLUS value "B" stamped on case.......... .002" (.038 mm)

  Total distance between bores................ 7.246" (184.05 mm)

2) Clean head of jig pillar and place dial indicator on pillar and zero indicator on pillar head. NOTE - Pillar is standard height of differential to settle bearings and move arm of dial indicator to machined face of jig and take a reading. Add this variation to the standard height to obtain total width of differential assembly. For example:

EXAMPLE:

  Differential assembly standard....................  6.972" (177.10 mm)

  PLUS indicator reading.............................    .008" (.203 mm)

  Total differential assembly..........................  6.980" (177.30 mm)

3) Subtract total width of differential assembly, found in 2) above, from total distance between the bores, found in 1) above. To this value, add specified bearing preload value and divide the result by 2 to obtain shim thickness equal values for both sides of assembly

EXAMPLE 

  Total distance between bores...................... 7.246" (184.05 mm)

  MINUS total differential assembly............... 6.980" (177.30 mm)

  Result......................................................... .266" (6.75 mm)

  PLUS bearing preload................................ .004" (.102 mm)

  Total shim thickness.................................... .270: (6.86 mm)

  Shim each side............................................ .135" (3.43 mm)

Backlash Adjustment - 1) Correct figure for backlash to be used with any particular ring and pinion is etched on rear face of ring gear. Increase shim thickness on opposite side to ring gear by this amount and decrease shim thickness on ring gear side by same amount.

EXAMPLE

  Calculated shim thickness............................  .135" (3.43 mm)

  MINUS backlash value...............................  .008" (.203 mm)

  Ring gear side shims....................................  .127" (3.23 mm)

  Calculated shim thickness............................  .135" (3.43 mm)

  PLUS backlash value..................................  .143" (3.62 mm)

2) Install differential in axle housing. Replace bearing caps and tighten bolts. Set up dial indicator to accurately measure backlash of ring gear. If backlash is not at value etched on ring gear, move shims from side to side to obtain correct value. A movement of .002" (.051 mm). shim thickness from one side of differential to the other will produce a variation in backlash of about .002" (.051 mm). Ensure absolute cleanliness during above operation to ensure accuracy. Continue installation in reverse of the removal procedure.

Read More..

Peugeot 404 1968 70 Drive Axles Repair Guide

DESCRIPTION

Peugeot split housing rear axle uses a steel worm drive pinion against a bronze ring gear. The axle housing is aluminum allow. The gear reduction is 4.2:1 (5X21). Both axle shaft tubes are bolted to rear axle housing. Removal of right axle tube provides "side cover" access to axle housing internal parts. Propeller shaft is enclosed and splined onto steel drive pinion of rear carrier.

AXLE RATIO & IDENTIFICATION

REMOVING REAR AXLES

Peugeot uses only one ratio rear axle which is identified by counting the teeth of the ring gear and dividing by the number of teeth on the pinion gear. The ring should have 21 teeth and the pinion should have 5 teeth, therefore the axle ratio is described as 5X21 or 4.2:1.

REMOVAL & INSTALLATION

AXLE SHAFTS & BEARINGS

Removal - 1) Lift vehicle from rear and place stands under axle shaft housings. Remove wheel and brake drum. Remove nuts securing flange (backing plate) to axle housing. Attach axle shaft sliding hammer (special tool 8.0601) to axle with lug nuts. Slide block outward against shoulder of tool to release axle shaft complete with flange and bearing.

SPECIAL TOOL FOR REMOVING
REAR AXLE BEARING

2) In order to facilitate removal of bearing collar, tap lightly on outside of collar before placing axle assembly in bearing press. Place axle shaft in press, splined end up and install press adaptor under flange. Apply sufficient pressure to end of axle shaft to remove both collar and bearing. NOTE - A special axle shaft bearing puller (special tool 8.0507) may be obtained from Peugeot distributor.

Installation - To install, reverse procedure using adaptor press on bearing and then press on new collar. When installing bearing and collar, observe the following precautions:

SEPARATING REAR AXLE HOUSING
FROM REAR CARRIER HOUSING

Always use new collar. Press bearing and collar on separately. Pressure required to press on new collar should be between 6½ and 8 tons. If pressure is not at least 6½ tons, that collar should not be used. Make certain that bearing and collar are both seated. Before installing axle into axle housing, coat axle bearing flange and axle housing with Permatex number 3. torque axle flange nuts and wheel lug nuts to specifications.

DIFFERENTIAL CARRIER

Removal - 1) With vehicle raised and supported, disconnect shock absorbers, stabilizer bar, parking brake cables and hydraulic brake hose (plug end of brake hose). Lift rear of body or lower rear end to remove coil springs. Remove exhaust pipe flange from exhaust manifold and exhaust pipe clamp from transmission housing.

DISASSEMBLING DIFFERENTIAL ASSEMBLY

2) Support transmission with jack. Remove upper bolt and two lower nuts of rear engine mount. Lower transmission small amount. NOTE - Do not allow engine oil pan to rest on steering housing. Using suitable socket wrench (special tool 8.0406), remove propeller tube ball joint cover attaching bolts. Separate tube from transmission.

3) Lift rear of vehicle enough to allow removal of rear axle and wheel assembly. Remove propeller tube from rear carrier housing. Remove wheels and axle shafts (as previously out-line). Disconnect brake backing plates and unbolt axle shaft tubes from rear carrier housing. Separate axle tubes from rear carrier by tapping gently on each tube flange with mallet.

REMOVING STEEL WORM GEAR
FROM CARRIER HOUSING

Installation - To install, reverse removal procedure and note the following: Rear engine mount must be free of grease, oil and paint. NOTE - Never use trichlorethylene to clean mount. Coat each side of mount with Permatex number 3. When installing coil springs, first coil should face to rear. NOTE - Coil springs are interchangeable. Bleed brakes after connecting brake lines.

OVERHAUL

DISASSEMBLY

1) With carrier housing removed and placed on its left side, remove differential from carrier housing. Place differential in soft jawed vise and remove bolts from side of ring gear (differential) assembly. Discard bolts, as new ones must be used on reassembly.

2) With differential removed from carrier housing, remove front oil seal, spacer and rear cap. To remove steel worm gear, dip housing in boiling water until housing is at temperature of water. Place housing in soft jawed vise with spline of worm gear facing downward through vise. Drive worm gear and bearing assembly downward and out of case. Use drift (special tool 8.0505) to remove outer races of differential bearings. NOTE - Do not interchange races.

REASSEMBLY AND ADJUSTMENT

1) On the steel drive pinion, coat both bearing seats with lubriplate and press on both front and rear bearings. NOTE - When pressing bearings, only apply pressure to inner race of bearings.

2) Place carrier housing in hot water until temperature reaches 190°F (88.0°C). With housing pre-heated, place housing in soft jawed vise with filing hole facing downward. Install pinion worm gear in housing. Hold pinion and install front spacer without its rubber ring. Hold assembly in place by means of cast iron plate, placed over spline end of pinion. Tighten plate with two diagonally opposed nuts.

PRESSING BEARINGS ONTO WORM
GEAR SHAFT

INSTALLING WORM GEAR
INTO CARRIER HOUSING

SEATING WORM GEAR

3) Turn housing upside down. Use drift to gently top bearing outer race (rear bearing), which will drive pinion toward front of case and ensure proper seating of pinion. Use depth measuring tool (special tool N), at rear of case, to determine depth of outer race. Use some tool to determine depth of rear cover. Difference between two measurements is amount of shims to install between two measurements is amount of shims to install between rear cover and housing. Install shims and rear cover, with groove facing either side. NOTE - Coat mating surfaces with Permatex number 3, but do not install gasket. After installing rear cover, worm gear should rotate freely. Remove front cast iron cover, installed over splined end of pinion worm gear. Install oil seal, rubber ring and front spacer; with groove facing either side.

PROCEDURE FOR DETERMINING THICKNESS OF
SHIMS FOR REAR WORM GEAR BEARING COVER

INSTALLING SIDE BEARING OUTER RACE

REASSEMBLING DIFFERENTIAL

4) Use drift (special tool l) to install side bearing outer races (one in housing and one in side cover) to depth of .040" (1.0 mm).

5) If pinion gears were removed from bronze ring gear, reinstall. Install differential side gears into ring gear side plate, using new composition thrust washers. Install ring gear side plates on to bronze gear with 5/16" (7.9 mm) holes aligned with end of pinion grearshaft. Bolt side plates together using six new bolts. NOTE - Bolt heads must be on side of ring gear marked with gear ratio. Torque bolts to specifications and stake bolts by punching metal into one castellation of each nut.

6) With side plates bolted onto bronze ring gear, install assembly into carrier housing (ratio marking should face upward). Differential is properly seated on lower side bearing if it turns freely by rotating worm gear (pinion). Install housing side cover with paper gasket coated with Permatex number 3. NOTE - Make sure locating boss is next to drain plug and hole of side cover, install spacers (see illustration).

INSTALLING SPECIAL TOOL ON LEFT SIDE COVER

7) Turn housing over (so housing is sitting on side cover) and align two 5/16" (7.9 mm) holes in side plate with corresponding holes in housing. Install special tool (K) in illustrated position with both fingers fitted through 5/16" (7.9 mm) holes of side plate. Secure clamp (special tool L) to press tool "K" correctly onto housing.

INSTALLING SPECIAL TOOLS & MEASURING  DEPTH OF LEFT SIDE BEARING

8) Turn assembly over, using special tool (K) as a support. Install special clamp (tool M) and apply slight pressure on outer race of side bearing. Hold depth gauge (tool N) against housing side and push plunger to touch outer race of side bearing. Lock  plunger and use gauge "N" to check bearing plate "A" to determine shim thickness. Remove clamp "M" and install shims. bearing plate and both locking straps. Tighten bolts (of locking straps) to specifications.

PREPARING DIFFERENTIAL FOR ADJUSTMENT

9) Turn assembly over so that it sits on side cover. Remove clamp "L" and tool "K". Install clamp "M" and apply slight pressure on outer race of side bearing. Use depth gauge (tool N) to determine shim thickness, as outlined in step 8). Remove clamp "M" and install shims. Install bearing plate and both locking straps. Tighten bolts, of locking straps, to specifications.

10) Remove spacers installed on side cover and install right hand axle housing.

INSTALLING SHIMS & LOCKING PLATES

Read More..

Austin Healey Sprite MG Midget 1968 74 Drive Axles Repair Guide

Models Covered:

• Austin Healey Sprite (1968-70)
• MG Midget (1968-74)

DESCRIPTION

Rear axles are hypoid design with center line of pinion set below centerline of ring gear. The axle shafts, pinion and differential assemblies can be serviced without removing axle from vehicle. All differential adjustments are performed using shims. No adjustment for axle shaft end play is necessary.

AXLE RATIO AND IDENTIFICATION

Only one basic axle design is used on these models. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.

REMOVAL AND INSTALLATION

AXLE SHAFT AND BEARINGS

1) With rear of vehicle raised and wheels removed, release handbrake and back off brake shoe adjusters. On models with disc wheels, remove brake drum locating screws and tap drums off hubs. Remove axle shaft retaining screw and withdraw shaft from hub assembly. On models with wire wheels, remove nuts securing drum to hub and tap brake drums off hub. Remove retaining screws securing hub extension flanges to hubs. Withdraw hub extensions and axle shafts.

2) Using suitable tool, remove hub nut and lock washer. Withdraw hub complete with bearing and seal. To install, repack hub bearings with grease and press hub into position. If paper washer or "O" ring was damaged on disassembly, they must be replaced. If seal was removed, drift it into position using suitable tool. Drift hub into axle housing using suitable tools and reinstall remainder of components in reverse of disassembly procedure.

PINION FLANGE AND SEAL

1) Mark propeller shaft and pinion flange for proper realignment and disconnect propeller shaft.Unscrew nut in center of flange, using suitable tool to prevent flange from rotating. Remove nut and washer and withdraw flange and pressed end cover from pinion shaft. Extract oil seal from axle housing.

2) Press new seal into axle housing with edge of sealing ring facing inwards. Replace flange and end cover, taking care not to damage edge of oil seal. Tighten pinion flange nut and reconnect propeller shaft, ensuring that index marks are lined up.

DIFFERENTIAL CARRIER

Drain rear axle and remove axle shafts. Mark propeller shaft and pinion shaft for correct reassembly and disconnect shaft. Remove nuts securing differential carrier to axle housing and withdraw complete carrier. To install, reverse removal procedure.

OVERHAUL

DISASSEMBLY

1) Check to ensure that differential bearing caps are marked to ensure correct replacement, then remove bearing cap nuts, washers and caps. Remove differential cage. Remove differential bearings from cage, using suitable tools and note that the thrust face of each bearing is marked "THRUST" and that shims are installed between inner ring of each bearing and differential cage. Knock back tabs of locking washers and unscrew bolts securing ring gear to differential cage, remove ring gear.

2) Tap out pin locating differential pinion shaft from ring gear side of cage as tapered pins are used. Drive out differential pinion shaft and remove pinions and thrust washers from cage. Remove pinion nut, flange and pressed end cover. Drive pinion shaft towards rear through carrier. Pinion shaft will come out with inner race and rollers for rear bearing, leaving outer race and complete front bearing in position.

3) Tap out inner race of front bearing and oil seal. Withdraw outer races using suitable tools. Slide off pinion sleeve and shims. Withdraw rear bearing inner race from pinion shaft using suitable tools. Note spacing washer against pinion head. Remove rear bearing outer race using suitable tools.

INSPECTION

Clean and inspect all components for worn or damaged parts. The ring and pinion gear must be replaced as a matched set if replacement of either is necessary.

REASSEMBLY AND ADJUSTMENT

CALIBRATING DIAL INDICATOR
(TOOL 18G-191)

Drive Pinion Depth - 1) Install outer bearing races in carrier using suitable tools. Smooth off pinion head with an oil-stone, taking care not to remove any markings etched on head. Assemble pinion and rear bearing with a washer of known thickness behind pinion head. Position pinion in carrier without bearing spacer and oil seal.

2) Install inner ring of front bearing and pinion flange and tighten nut slowly until a bearing preload of 8-10 INCH lbs. (9-12 kgcm) is obtained. Using tool 18G-191, adjust dial indicator to zero on machined step "A" of setting block (see illustration). Place dial indicator and base of tool on head of pinion and position tool so dial indicator feeler rests on center of differential bearing bore. Note any variation from zero. Now swing indicator to other bearing bore and again note variation from zero. Average the two variation together.

3) Take into consideration any variation in pinion head thickness. This will be shown as an unbracketed figure etched on pinion head and will always be minus. If no unbracketed figure is shown, pinion head is of nominal thickness. Using average dial indicator reading just obtained and the unbracketed figure from pinion head, perform the following calculation: If indicator reading is minus, add indicator reading to pinion head reading and REDUCE known washer thickness by this amount.

EXAMPLE

   Indicator Reading..................................  -.002"

   Pinion Marking.....................................  -.005"

   Variation from Nominal.........................  -.007"

Reduce known washer thickness by this amount.

4) If indicator reading is plus and numerically LESS than pinion marking, REDUCE the known washer thickness by the difference.

EXAMPLE:

   Pinion Marking.....................................  -.005"

   Indicator Reading.................................  +.003"

   Variation From Nominal.......................  -.002"

Reduce known washer thickness by this amount.

5) If indicator reading is plus and numerically GREATER than pinion marking. INCREASE the known washer thickness by the difference.

EXAMPLE:

   Indicator Reading.................................  +.008"

   Pinion Marking.....................................  -.003"

   Variation from Nominal........................  +.005"

Increase known washer thickness by this amount.

SIDE BEARING PRELOAD DIMENSIONS

6) The only cases where no changes are required to washer thickness are when indicator reading is PLUS and NUMERICALLY EQUAL to unbracketed pinion marking, or indicator reading is zero and there is no unbracketed marking on pinion head. Allowance should now be made as follows for mounting distance marked on pinion head in a rectangular bracket as follows:

7) If marking is a PLUS figure, REDUCE washer thickness by on equal amount. If marking is a MINUS figure, INCREASE washer thickness by on equal amount. A tolerance of .001" (.03 mm) is allowed in thickness of washer finally installed.

Pinion Bearing Preload - Install washer of thickness just calculated under pinion head and assemble pinion with bearings, pinion sleeve, oil seal, flange and nut. Pinion sleeve is of collapsible design and can only be used once. Therefore, the following procedure should be done with care or new sleeve will be required. Slowly tighten flange nut to specifications while holding flange to prevent rotation. During tightening process, occasionally check pinion bearing preload. When nut is tightened to specifications, preload should be to specifications. Installation of pinion is now complete.

CHECKING BEARING THICKNESS VARIATION
(TOOL 18G-191)

Side Bearing Preload - 1) This method of setting position of ring gear assembly depends on marking given on differential gear carrier and case. The dimension to be considered are (see illustration): "A" - The dimension from center line to bearing on right side. Variation in dimension "A" is stamped on carrier adjacent to right side bearing bore. "B" - The dimension from center line to bearing on left side. Variation is stamped on left side bearing bore. "C" - Dimension from bearing on one side of cage to bearing on other side and "D" - Dimension from rear face of ring gear to bearing on opposite side. Variation on "C" & "D" dimension are stamped on machined face of differential cage.

2) It is possible to calculate shim thickness required on left side by use of follwoing formula

                                            A+D-C+.002"

Substituting the actual variations shown, this formula gives shim thickness required to compensate for variation in machining plus the extra .002" (.05 mm) to give necessary bearing preload. In addition, allowance must be made for variations in bearing thickness in the following manner:

CHECKING BACKLASH
(TOOL 18G-191)

3) Rest bearing with inner race over recess and thrust face downwards on surface plate of tool 18G-191. Place dial indicator on surface plate and zero indicator on step "A" of gauge block of tool 18G-191. Swing indicator over until it rests on plain surface of inner bearing race. Hold inner race down against balls and note indicator reading. Indicator will normally indicate a negative reading. This negative variation should be ADDED to the shim pack previously calculated for that side of the differential.

4) To calculate shim thickness for the right side, use the following formula:

                                           B-D+.006"

substituting the actual values for "B" and "D" as described in 1). Again, final allowance must be made for variation in bearing thickness as described in 3) above.

5) When a framed number is marked on back of ring gear, e.g. +2, it must be taken into account before assembling shims and bearings to differential cage. If, for example, the mark +2, then shims of .002" must be transferred from left (ring gear) side to right side. If marking is -2, shims of .002" must be moved from right to left side.

Backlash Adjustment - 1) Assemble bearings (thrust faces outwards) and shims as calculated to differential cage. Bolt ring gear to differential cage. Bolt ring gear to differential cage but do not knock over locking tabs. Mount assembly on two "V" blocks and check runout by means of dial indicator. If runout  exceeds specifications, remove ring gear and check joint faces on cage ring gear for any particles of dirt. If parts are thoroughly cleaned it is unlikely that ring gear will not run true. Tighten bolts and knock over locking washers.

2) Install differential to carrier. Replace bearing caps and tighten nuts. Bolt surface plate of tool 18G-191 to carrier flange and mount a dial indicator in such way that an accurate backlash figure may be obtained. Correct figure for backlash to be used with any particular gear and pinion is etched on rear face of ring gear. A movement of .002" (.05 mm) shim thickness from one side of differential cage to the other will produce a variation  in backlash of about .002" (.06 mm). Use care to ensure absolute cleanliness during the operation as dirt can result in inaccurate readings and poor settings. Carrier may now be installed in rear axle housing.

Read More..