Measure and record inner pinion bearing shim thickness. Move dial indicator base and mount in line with ring gear. Apply grease to Step Bore Plate and assemble Mandrel and forcing screw in between side gears. Remove rear brake caliper retaining bolts, and wire caliper aside. Differential Case Ensure hubs where bearings mount are smooth. Two sets of multiple disc clutches control limited slip differential action.
Position shift fork in axle housing. Disconnect rear stabilizer bar at links. Failure to do so can result in unexpected inflation or deflation of air suspension, which can result in shifting of vehicle during servicing. Install left bearing cap and bolts. Remove pinion shaft lock bolt. Rotate gauge block several times to seat bearings. Remove drive pinion by tapping with soft-faced mallet.
Remove differential case from carrier to install ring gear. Turn ring gear without turning pinion gear to measure backlash. Remove drive shaft bolts, and wire drive shaft aside. . Check all bearings and races for nicks, roller end wear, grooves or damage. Mark pinion flange in relation to pinion shaft for installation reference.
Hold rear anti-lock brake sensor on both sides and install. Remove pinion gears and thrust washers. Remove pinion shaft lock bolt and pinion shaft. Shims are available in various thicknesses. Assemble Pinion Depth Gauge T79P-4020-A.
Mark bearing caps from installation reference. Bearing Races Check bearing races for scoring or galling. Install bearing caps and retaining bolts. Ensure shims are seated and gear assembly turns freely. Of Stripes Shim Thickness In. Remove axle housing retaining bolts. Sample page; As second generation factory manual was designed almost fifteen years ago therefore many customers believe that latest features are not accessible.
Move ring gear away from pinion gear as much as possible. Replace pinion gear and ring gear as a set. Place pre-selected shim on pinion shaft. Tighten cover bolts to specification in a crisscross pattern. Keep bearing mounting surface above vise jaws. To install, reverse removal procedure. Install pinion shaft roll pin.
Tighten all nuts and bolts to specification. Also, ensure front axle clutch is engaging completely. Fill axle housing with lubricant until level with bottom of fill hole. Install front pinion bearing into front bearing cup. Remove pinion gears ans thrust washers.
Remove forcing screw, Mandrel and Step Bore Plate from differential case. Connect rear end of drive shaft to pinion flange, aligning scribed marks. With depth micrometer positioned on bearing cone, measure height of each individual bearing assembly. Anti-Lock Brake Sensor Check sensor pole piece for loose metal particles. Ensure bearing bore is clean and undamaged. Tighten tool handle to 20 ft. Measure total end play and record on Line-A of differential bearing shim selection procedure work sheet.
Align marks on pinion flange and pinion stem. Axle is of integral carrier housing, hypoid gear type. Push differential case left and right as far as possible. Apply a small amount of lubricant to pinion flange splines. Turn nose of axle housing up. A space is provided between ring gear and exciter ring for measuring ring gear runout. Remove left stub axle retaining clip inside differential assembly.
Friction modifier must be added to prevent damage to differential. Drive pinion and ring gear bearing adjustments are all accomplished with shims. Gears Examine pinion and ring gear teeth for scoring, excessive wear, and excessive chipping. Ensure ring is free of any nicks or burrs. Failure to do so can result in unexpected inflation or deflation of air suspension, which can result in shifting of vehicle during these operations. Pinion Flange Ensure flange half-rounds and lugs have not been damaged. End of flange contacting bearing, counterbore and seal surface must be smooth and free of damage.