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REMOVAL
(1) Remove differential case from axle housing. (2) Remove differential bearings from the case with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 48).Fig.48DIFFERENTIALBEARINGPULLER
1 - PULLER 2 - ADAPTERS 3 - BEARING 4 - DIFFERENTIAL 5 - PLUG
Fig.47CLUTCHPACKANDUPPERSIDEGEAR
1 - SIDE GEAR AND CLUTCH PACK 2 - DIFFERENTIAL CASE 3 - LOWER DISC
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in side gears and verify
pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until pinion mate shaft holes in pinion gears align with holes in case.
NOTE: screw in order to install the pinion gears.
If necessary, slightly tighten the forcing
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to ver- ify alignment.
REAR AXLE - 9 1/4
3 - 94
DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION(1) Install differential side bearings with Installer
C-4213 and Handle C-4171 (Fig. 49).
DR
Fig.50RINGGEAR
1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER
(8) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(9) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
companion flange with Remover
(11) Remove C-452 (Fig. 51).
Fig.49DIFFERENTIALCASEBEARING
1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER
(2) Install differential case into housing.
PINION GEAR/RING GEAR/ TONE RING REMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replac- ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts. (4) Remove differential from the differential hous-
ing.
case.
jaw protectors..
(5) Place differential case in a vise with soft metal
(6) Remove ring gear bolts from the differential
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 50).
Fig.51COMPANIONFLANGE
1 - COMPANION FLANGE 2 - REMOVER
(12) Remove pinion gear from the housing (Fig.
52).
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 95
(16) Remove rear pinion bearing cup from housing (Fig. 54) with Remover C-4307 and Handle C-4171.
Fig.52PINIONGEAR
1 - RAWHIDE HAMMER
(13) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
(14) Remove front pinion bearing and oil slinger if
equipped.
(15) Remove
front
pinion bearing
cup with
Remover C-4345 and Handle C-4171 (Fig. 53).
Fig.54REARPINIONBEARINGCUP
1 - DRIVER 2 - HANDLE
(17) Remove collapsible spacer from the pinion
shaft (Fig. 55).
Fig.53FRONTPINIONBEARINGCUP
1 - REMOVER 2 - HANDLE
Fig.55COLLAPSIBLESPACER
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
REAR AXLE - 9 1/4
3 - 96
PINION GEAR/RING GEAR/TONE RING (Continued)DR
(18) Remove rear pinion bearing (Fig. 56) from the pinion shaft with Puller C-293-PA and Adapters C-293-37.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a matched set. Do not replace one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjust- ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent stick lubricant to outside surface of the pinion bearing cups.
(2) Install rear pinion bearing cup (Fig. 58) with Installer C-4308 and Driver Handle C-4171 and ver- ify cup is seated.
Fig.56REARPINIONBEARING
1 - PULLER 2 - VISE 3 - ADAPTERS 4 - PINION SHAFT
(19) Remove pinion depth shim (Fig. 57) from the
pinion shaft and record shim thickness.
Fig.58REARPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
(3) Install front pinion bearing cup (Fig. 59) with Installer D-129 and Handle C-4171 and verify cup is seated.
(4) Lubricate and install front pinion bearing into
the housing.
(5) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig. 60).
Fig.57PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 97
Fig.59FRONTPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
Fig.61PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
Fig.60PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER 3 - HOUSING
(6) Install pinion depth shim (Fig. 61) on the pin-
ion gear shaft.
(7) Install rear bearing on the pinion (Fig. 62) with
Installer C-3095-A and a press.
Fig.62REARPINIONBEARING
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
REAR AXLE - 9 1/4
3 - 98
PINION GEAR/RING GEAR/TONE RING (Continued)(8) Install a new collapsible spacer on the pinion
shaft (Fig. 63).
DR
Fig.64PINIONNUT
1 - DIFFERENTIAL HOUSING 2 - HOLDER 3 - TORQUE WRENCH
(16) Check pinion rotating torque with an inch pound torque wrench (Fig. 65). The pinion rotating torque should be: † Original Bearings: 1 to 3 N·m (10 to 20 in. lbs.). † New Bearings: 2 to 5 N·m (15 to 35 in. lbs.).
Fig.63COLLAPSIBLESPACER
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
(9) Lubricate rear pinion bearing and install pin-
ion gear into the housing.
C-3718 and Holder 6719.
(10) Install
companion flange with Installer
(11) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(12) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
(13) Install companion flange washer and a new nut on the pinion and tighten the nut until there is zero bearing end-play.
(14) With a torque wrench tighten the nut to 285
N·m (210 ft. lbs.) (Fig. 64).
CAUTION: Never loosen pinion nut to decrease pin- ion rotating torque and never exceed specified pre- load torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure pinion rotating torque frequently to avoid over crushing the collapsible spacer.
Fig.65PINIONROTATIONTORQUE
1 - COMPANION FLANGE 2 - TORQUE WRENCH
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 9 1/4
3 - 99
(17) Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position.
(18) Position ring gear on the differential case and start two ring gear bolts. This will provide case-to- ring gear bolt hole alignment.
(19) Invert the differential case in the vise. (20) Install new ring gear bolts and alternately
tighten to 156 N·m (115 ft. lbs.) (Fig. 66).
CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.
(21) Install differential in housing and verify gear
mesh, backlash and contact pattern.
(22) Install axle shafts. (23) Install differential cover and fill with gear
(24) Install propeller shaft with reference marks
lubricant.
aligned.
Fig.66RINGGEARBOLTS
1 - TORQUE WRENCH 2 - RING GEAR BOLTS 3 - RING GEAR 4 - DIFFERENTIAL CASE
3 - 100
REAR AXLE - 10 1/2 AA
REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page
DR
page
REAR AXLE - 10 1/2 AA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 100
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 103
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 104
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 108
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 108AXLE SHAFTS
REMOVAL INSTALLATION AXLE BEARINGS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . . . . . . . . . . 111OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 114
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 115
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117DIFFERENTIAL TRAC-RITE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 118
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 120DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 112REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121PINION SEAL
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 123DIFFERENTIAL DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . 114
REAR AXLE - 10 1/2 AA DESCRIPTION
The axle consists of a cast iron center casting dif- ferential housing with axle shaft tubes extending from each side. The tubes are pressed into the differ- ential housing and welded. The design has the cen- terline of the pinion set below the centerline of the ring gear. The axle is a full floating axle where the loads are supported by the axle housing tubes. The axle has a vent used to relieve internal pressure caused by lubricant vaporization and internal expan- sion.
OPERATION
The axle receives power from the propeller shaft. The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case. The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are splined to the axle shafts.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri- cant, incorrect backlash, incorrect pinion depth, tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are accelera- tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then acceler- ate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly:
† Check for insufficient lubricant. † Incorrect ring gear backlash. † Gear damage. Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during vehi- cle turns. A worn pinion shaft can also cause a snap- ping or a knocking noise.
DR REAR AXLE - 10 1/2 AA (Continued) BEARING NOISE
The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound. Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differen- tial. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front pinion bearing is the source.
Worn or damaged differential bearings usually pro- duce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differen- tial bearing noise is also constant and varies only with vehicle speed.
Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn U-joint or by worn side-gear thrust washers. A worn pinion shaft bore will also cause low speed knock.
VIBRATION
caused by a:
Vibration at the rear of the vehicle is usually † Damaged drive shaft. † Missing drive shaft balance weight(s).
REAR AXLE - 10 1/2 AA
3 - 101
† Worn or out-of-balance wheels. † Loose wheel lug nuts. † Worn U-joint(s). † Loose/broken springs. † Damaged axle shaft bearing(s). † Loose pinion gear nut. † Excessive pinion yoke run out. † Bent axle shaft(s). Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be a rearend vibra- tion. Do not overlook engine accessories, brackets and drive belts.
NOTE: All driveline components should be exam- ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: † High engine idle speed. † Transmission shift operation. † Loose engine/transmission/transfer case mounts. † Worn U-joints. † Loose spring mounts. † Loose pinion gear nut and yoke. † Excessive ring gear backlash. † Excessive side gear to case clearance. The source of a snap or a clunk noise can be deter- mined with the assistance of a helper. Raise the vehi- cle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.
DIAGNOSTIC CHART
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
1. Inspect axle tube alignment. Correct as necessary.
2. Bent or sprung axle shaft.
2. Inspect and correct as necessary.
REAR AXLE - 10 1/2 AA
3 - 102
REAR AXLE - 10 1/2 AA (Continued)DR
Condition
Possible Causes
Correction
Axle Shaft Broke
1. Misaligned axle tube.
2 Vehicle overloaded.
3. Erratic clutch operation.
4. Grabbing clutch.
Differential Cracked
1. Improper adjustment of the differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
Differential Gears Scored
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one wheel/tire.
Loss Of Lubricant
1. Lubricant level too high.
2. Worn axle shaft seals. 3. Cracked differential housing. 4. Worn pinion seal. 5. Worn/scored yoke. 6. Axle cover not properly sealed.
1. Replace the broken shaft after correcting tube mis-alignment.
2. Replace broken shaft and avoid excessive weight on vehicle. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Replace broken shaft and inspect and repair clutch as necessary.
1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.
2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly. 3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight. 4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.
1. Replace scored gears. Fill differential with the correct fluid type and quantity.
2. Replace scored gears. Fill differential with the correct fluid type and quantity. 3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.
1. Drain lubricant to the correct level.
2. Replace seals. 3. Repair as necessary. 4. Replace seal. 5. Replace yoke and seal. 6. Remove, clean, and re-seal cover.
Axle Overheating
1. Lubricant level low.
1. Fill differential to correct level.
2. Improper grade of lubricant.
3. Bearing pre-loads too high. 4. Insufficient ring gear backlash.
2. Fill differential with the correct fluid type and quantity. 3. Re-adjust bearing pre-loads. 4. Re-adjust ring gear backlash.
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 103
Condition
Possible Causes
Correction
Gear Teeth Broke
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
Axle Noise
1. Insufficient lubricant.
2. Improper ring gear and pinion adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or pinion. 5. Loose pinion bearings. 6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap bolts.
9. Housing not machined properly.
REMOVAL
INSTALLATION
1. Replace gears. Examine other gears and bearings for possible damage.
2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation. 3. Replace gears and examine remaining parts for damage. 4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.
1. Fill differential with the correct fluid type and quantity. 2. Check ring gear and pinion contact pattern. Adjust backlash or pinion depth. 3. Replace gears with a matched ring gear and pinion. 4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load. 6. Adjust differential bearing pre-load. 7. Measure ring gear run-out. Replace components as necessary. 8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification. 9. Replace housing.
(1) Raise and support the vehicle. (2) Position a lifting device under the axle. (3) Secure axle to device. (4) Remove wheels and tires assemblies. (5) Remove RWAL sensor from the differential
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install axle U-bolts and tighten to 149 N·m
(3) Install shock absorbers to axle and tighten to
housing.
brackets.
and axle vent hose.
(6) Remove brake hose at the axle junction block
(4) Install the RWAL sensor to the differential
(7) Disconnect parking brake cables and cable
(5) Connect the parking brake cables and cable
(8) Remove brake calipers and rotors. (9) Mark propeller shaft and companion flange for
(6) Install brake calipers. (7) Connect brake hose to the axle junction block
installation alignment reference.
(10) Remove propeller shaft. (11) Remove shock absorbers from axle. (12) Remove U-bolts from axle. (13) Separate the axle from the vehicle.
and axle vent hose.
(8) Align propeller shaft and pinion companion flange reference marks and tighten companion flange bolts to 115 N·m (85 ft. lbs.).
(9) Install the wheels and tires.
(110 ft. lbs.).
specification.
housing.
brackets.
DR
ing torque should be 1.7-2.26 N·m (15-20 in. lbs.) (Fig. 1).
REAR AXLE - 10 1/2 AA
3 - 104
REAR AXLE - 10 1/2 AA (Continued)(10) Fill differential to specifications. (11) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched sets only. Compensation for pinion depth variance is achieved with a select shim. The shim is located between the rear pinion bearing and the pinion gear head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indi- cator C-3339 (Fig. 1).
Fig.2PINIONHEIGHTBLOCK
1 - PINION BLOCK 2 - PINION HEIGHT BLOCK
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 3).
(5) Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 165 N·m (122 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
Fig.3GAUGETOOLSINHOUSING
1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on the pinion height block. Hold scooter block and zero the dial indicator.
Fig.1PINIONGEARDEPTHGAUGETOOLS
1 - DIAL INDICATOR 2 - ARBOR 3 - PINION HEIGHT BLOCK 4 - CONE 5 - SCREW 6 - PINION BLOCK 7 - SCOOTER BLOCK 8 - ARBOR DISC
(1) Assemble Pinion Height Block 6739, Pinion Block 8899 and rear pinion bearing onto Screw 6741
(Fig. 1).(2) Insert assembled height gauge components, rear bearing and screw into the housing through pin- ion bearing cups (Fig. 2).
(3) Install
front pinion bearing and install the Cone-nut 6740 hand tight. Then check tool rotating torque with an inch pound torque wrench. The rotat-
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 105
(8) Slowly slide the scooter block across the pinion height block over to the arbor (Fig. 4). Move the scooter block till dial indicator crests the arbor, then record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
Fig.4PINIONGEARDEPTHMEASUREMENT
1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR
DIFFERENTIAL CASE BEARING PRELOAD AND GEAR BACKLASH
Fig.5ADJUSTERLOCKBOLT
1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT 4 - BEARING CAP BOLT
Backlash is adjusted by moving the adjusters in and out or both. By moving the adjusters the case/ ring gear will move closer or further away from the pinion. In most cases this adjustment can be used to achieve the correct gear tooth pattern and set the case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps. (3) Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 (Fig. 6) until they make contact with the differ- ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear
side adjuster
firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.
Fig.6ADJUSTERSPANNERWRENCH
1 - WRENCH 2 - DIFFERENTIAL
(9) Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup, then tighten it until it makes contact. (10) Tighten pinion gear side adjuster an addi- tional:† New Bearings: 6 Adjuster Holes † Original Bearings: 4 Adjuster Holes (11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
DR
† Gear contact pattern correct (Fig. 8). Backlash
and pinion depth is correct.
REAR AXLE - 10 1/2 AA
3 - 106
REAR AXLE - 10 1/2 AA (Continued)(12) Tighten bearing cap bolts to 115 N·m (85 ft.
(13) Tighten adjuster lock bolts to 33 N·m (24 ft.
lbs.).
lbs.).
(14) Measure ring gear backlash with a Dial Indi- cator C-3339 and Dial Indicator Stud L-4438 at eight points around the drive side of the ring gear (Fig. 7). The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005- 0.007 in).NOTE: Backlash measurement should not vary more than 0.05 mm (0.002 in) between measuring points. If measurement does vary inspect the gears for burrs, the differential case flange and ring gear mounting.
Fig.8CORRECTCONTACTPATTERN
† Ring gear too far away from pinion gear (Fig. 9). Decrease the backlash, by moving the ring closer to the pinion gear using the adjusters.
Fig.7RINGGEARBACKLASH
1 - COAST SIDE TOE 2 - DRIVE SIDE HEEL
Fig.9INCORRECTBACKLASH
1 - DIAL INDICATOR 2 - RING GEAR
GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor- rect running position of the ring and pinion gears. This will produce low noise and long gear life. Gears which are not positioned properly may be noisy and have shorten gear life.
(1) Wipe clean each tooth of the ring gear. (2) Apply gear marking compound to all of the ring
gear teeth.
tion.
(3) Verify bearing cap bolts are torque specifica-
(4) Apply parking brakes lightly to create at 14
N·m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
† Ring gear too close to pinion gear (Fig. 10). Increase the backlash, by moving the ring away from the pinion gear using the adjusters.
Fig.10INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL
DR REAR AXLE - 10 1/2 AA (Continued) † Ring gear too far away from pinion gear (Fig. 11). Decrease the backlash, by moving the ring closer to the pinion gear using the adjusters.
REAR AXLE - 10 1/2 AA
3 - 107
† Pinion gear is set too low (Fig. 13). Increase the pinion gear height, by increasing the pinion depth shim thickness.
Fig.11INCORRECTBACKLASH
1 - DRIVE SIDE HEEL 2 - COAST SIDE HEEL
† Ring gear too close to pinion gear (Fig. 12). Increase the backlash, by moving the ring away from the pinion gear using the adjusters.
Fig.13LOWPINIONHEIGHT
† Pinion gear is set too high (Fig. 14). Decrease the pinion depth, by decreasing the pinion depth shim thickness.
Fig.12INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE TOE
Fig.14HIGHPINIONHEIGHT
REAR AXLE - 10 1/2 AA
3 - 108
REAR AXLE - 10 1/2 AA (Continued) SPECIFICATIONSDR
AXLE SPECIFICATIONS
DESCRIPTION
Axle Ratio
Ring Gear Diameter Ring Gear Backlash
Pinion Bearing Preload - New Bearings
Pinion Bearing Preload - Original Bearings
Pinion Bearing Preload + Diff Case Bearing Preload -
New Bearings
Pinion Bearing Preload + Diff Case Bearing Preload -
Original Bearings
SPECIFICATION
3.73, 4.10
266 mm (10.5 in.)
0.13-0.18 mm (0.005-0.007 in.) 1.69-2.82 N·m (15-25 in. lbs.)
1-2 N·m (10-20 in. lbs.)
3.4-5.6 N·m (30-50 in. lbs.)
2.8-5.1 N·m (25-45 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION Fill Hole Plug
Differential Cover Bolts
Bearing Cap Bolts Ring Gear Bolts Axle Flange Bolts Adjuster Lock Bolt
SPECIAL TOOLS
N·m 32
40
165
237
129
25Ft. Lbs.
In. Lbs.
24
30
122
175
95
18DIALINDICATORSETC-3339
HANDLEC-4171
DIALINDICATORSTUDL-4438
SPLITTER1130
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 109
PULLERC-293-PA
BRIDGE938
PINIONDEPTHGAUGE6730
ADAPTERS8879
GAUGEBLOCK8899
ADJUSTERWRENCH8883
ARBORDISCS6732
BEARINGINSTALLER8956
REAR AXLE - 10 1/2 AA
3 - 110
REAR AXLE - 10 1/2 AA (Continued)DR
PINIONINSTALLER8981
FLANGEPULLER8992
CUPINSTALLER8959
FLANGEWRENCH8979
CUPINSTALLER8960
PINIONDRIVER8977
CUPINSTALLER8961
PLUG8888
DR REAR AXLE - 10 1/2 AA (Continued)
REAR AXLE - 10 1/2 AA
3 - 111
SEALINSTALLER8896
SOCKET8954
AXLE SHAFTS REMOVAL
(1) Remove axle shaft flange bolts (Fig. 15).
SEALINSTALLER8963
CUPINSTALLER8962
BEARINGINSTALLERMD-998805
Fig.15AXLEFLANGEBOLTS
1 - AXLE FLANGE 2 - FLANGE BOLT
(2) Slide axle shaft out of the axle tube. (3) Remove axle shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use Mopar Lock N’ Seal or LoctiteT 242 on cleaned existing bolts.
(1) Clean axle flange and hub. (2) Install new axle shaft gasket. (3) Slide axle shaft into the axle tube. (4) Install axle shaft flange bolts and tighten to
129 N·m ( 95 ft. lbs.).
3 - 112
REAR AXLE - 10 1/2 AA
DR
AXLE BEARINGS REMOVAL
(1) Remove axle shaft flange bolts and remove axle
(2) Remove retianer ring (Fig. 16) from the axle
shaft.
shaft tube.
(4) Remove hub bearing nut with Socket 8954. (5) Remove hub and bearings from the axle. (6) Pry out hub bearing seal from the back of the
hub.
NOTE: The inner part of the seal may stay on the axle tube (Fig. 18). This part must also be removed.
Fig.16RETAINERRING
1 - RETAINER RING 2 - LOCKING KEY 3 - BEARING NUT
Fig.18INNERPARTOFSEAL
1 - PRY BAR 2 - AXLE TUBE 3 - REMAINING SEAL
(7) Remove rear bearing. (8) Remove hub bearing cups with a hammer and
drift.
(3) Remove hub bearing nut locking key (Fig. 17).
INSTALLATION
(1) Install outer hub bearing cup with Installer
8961 and Handle C-4171.
8962 and Handle C-4171.
(2) Install
inner hub bearing cup with Installer
(3) Pack bearings with the appropriate grease. (4) Install rear bearing and install new grease
seal with Installer 8963 and Handle C-4171.
(5) Slide hub on the axle tube and install front
bearing into the hub.
(6) Install hub bearing nut with Socket 8954 and tighten to 30 N·m (22 ft. lbs.) while rotating the hub (Fig. 19).
(7) Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key.
NOTE: End play (0.001-0.010 in.).
should be
0.025-0.25 mm
Fig.17LOCKINGKEY
1 - BEARING NUT 2 - LOCKING KEY 3 - AXLE TUBE
(8) Install retainer ring with ring end in the key
(9) Install new axle shaft gasket and install axle
slot.
shaft.
DR AXLE BEARINGS (Continued)
REAR AXLE - 10 1/2 AA
3 - 113
Fig.19HUBNUTSOCKET
Fig.21FLANGEWRENCH
1 - SOCKET 2 - TORQUE WRENCH
PINION SEAL REMOVAL
1 - PINION FLANGE 2 - FLANGE WRENCH
(6) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 22).
(1) Remove axle shafts. (2) Mark propeller shaft and pinion flange for
installation reference and remove shaft.
(3) Rotate pinion gear three or four times. (4) Measure and record the amount of torque nec- essary to rotate the pinion gear with an inch pound torque wrench (Fig. 20).
Fig.22PINIONFLANGEPULLER
1 - PINION FLANGE 2 - PULLER
(7) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
Fig.20PINIONROTATINGTORQUE
1 - PINION FLANGE 2 - TORQUE WRENCH
(5) Hold pinion flange with Flange Wrench 8979
(Fig. 21) and remove pinion flange nut and washer.INSTALLATION
(1) Install new pinion seal with Installer 8896 and
Handle C-4171 (Fig. 23).
(2) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer and new pinion nut. (5) Hold flange with Flange Wrench 8979 (Fig. 24) and tighten pinion nut until pinion end play is taken up.
REAR AXLE - 10 1/2 AA
3 - 114
PINION SEAL (Continued)Fig.23PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
DR
DIFFERENTIAL DESCRIPTION
The differential case is a one-piece design. The dif- ferential pinion shaft is retained with a snap ring. Differential bearing preload and ring gear backlash is adjusted by the use of adjusters. The adjuster are between the differential bearings and the differential housing. Pinion bearing preload is set and main- tained by the use of a collapsible spacer. The stamped steel cover provides a means for inspection and servicing the differential.
OPERATION
During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 25).
Fig.24FLANGEWRENCH
1 - FLANGE WRENCH 2 - PINION FLANGE
(6) Rotate pinion several times to seat bearings. (7) Measure pinion rotating torque with an inch pound torque wrench and compare it to recorded measurement.
(8) Tighten pinion nut in small increments, until pinion rotating torque is 0.40-0.57 N·m (3-5 in. lbs.) greater than recorded measurement.
(9) Rotate pinion several times then verify pinion
rotating torque again.
(10) Install axle shafts. (11) Install propeller shaft with reference marks
aligned.
(12) Check and fill differential if necessary.
Fig.25DIFFERENTIAL-STRAIGHTAHEADDRIVING 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE
When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 26). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.
DR DIFFERENTIAL (Continued)
REAR AXLE - 10 1/2 AA
3 - 115
(7) Loosen differential bearing adjusters (Fig. 28)
with Spanner Wrench 8883.
Fig.26DIFFERENTIAL-ONTURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
REMOVAL
(1) Remove lubricant fill hole plug from the differ-
ential housing cover.
(2) Remove differential housing cover and drain
the lubricant from housing.
(3) Remove axle shafts. (4) Remove adjuster lock bolts and adjuster locks
(Fig. 27).
Fig.27ADJUSTERLOCKS
1 - LOCK BOLT 2 - ADJUSTER LOCK 3 - ADJUSTER 4 - BEARING CAP
(5) Mark bearing caps left and right for installa-
(6) Remove bearing cap bolts and remove bearing
tion reference.
caps.
Fig.28BEARINGADJUSTERS
1 - BEARING CUP 2 - ADJUSTER 3 - BEARING CUP 4 - ADJUSTER
(8) Remove differential case from the housing. (9) Remove bearing cups and tag them left and
right for installation reference.
DISASSEMBLY
(1) Remove pinion shaft with a hammer and punch from the side with the hole in the pinion shaft (Fig. 29).
Fig.29PINIONSHAFT
1 - PINION GEAR 2 - PINION SHAFT 3 - RING GEAR 4 - EXCITER RING
REAR AXLE - 10 1/2 AA
3 - 116
DIFFERENTIAL (Continued)(2) Rotate one pinion gear with thrust washer (Fig. 30) to the differential window and remove the gear.
DR
Fig.30FRISTPINIONGEAR
1 - DIFFERNTIAL CASE WINDOW 2 - PINION GEAR 3 - THRUST WASHER
(3) Rotate the other pinion gear with thrust washer (Fig. 31) to the differential window and remove the gear.
Fig.32SIDEGEARS
1 - SIDE GEAR 2 - SIDE GEAR 3 - PINION GEARS
ASSEMBLY
NOTE: If the same gears and thrust washers are being used, install them into their orignial locations.
(1) Lubricate all differential components with axle
(2) Install differential side gears and thrust wash-
lubricant.
ers (Fig. 33).
Fig.31SECONDPINIONGEAR
1 - DIFFERENTIAL WINDOW 2 - THRUST WASHER 3 - PINION GEAR
(4) Remove differential side gears and thrust
washers (Fig. 32).
Fig.33SIDEGEAR
1 - DIFFERENTIAL WINDOW 2 - SIDE GEAR
(3) Install first pinion gear into the differential window and side gears. Rotate the pinion gear to the back of the case (Fig. 34).
DR DIFFERENTIAL (Continued)
Fig.34PINIONGEAR
1 - DIFFERENTIAL WINDOW 2 - SIDE GEARS 3 - PINION GEAR
REAR AXLE - 10 1/2 AA
3 - 117
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or gasoline for cleaning.
(2) Lubricate differential case bearing. (3) Install differential case with bearings cups into
the housing.
NOTE: A light coat of grease on the cups will hold them in place during installation.
(4) Install bearing caps and bolts (Fig. 36). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this time.
(4) Install
the other pinion gear and thrust washer. Rotate the gears to align hole in the pinion gears with hole in the differential case.
(5) Slide pinion shaft into the case and through the pinion gears. Tap the shaft to seat the pinion shaft snap-ring into the case (Fig. 35).
Fig.36CASEBEARINGCAP
1 - DIFFERENTIAL HOUSING 2 - BEARING CAP 3 - ADJUSTER
Fig.35PINIONSHAFTINSTALLATION
1 - PINION SHAFT SNAP-RING 2 - SIDE GEAR 3 - PINION GEAR 4 - PINION SHAFT
(5) Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential bearings/cups.
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
REAR AXLE - 10 1/2 AA
3 - 118
DIFFERENTIAL (Continued)(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear
side adjuster
firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup. (13) Tighten pinion gear side adjuster an addi- tional:† New Bearings 6 Adjuster Holes † Original Bearings 4 Adjuster Holes (14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 165 N·m (122 ft.
(16) Tighten adjuster lock bolts to 25 N·m (18 ft.
lbs.).
lbs.) (Fig. 37).
Fig.37ADJUSTERLOCKBOLT
1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT 4 - BEARING CAP BOLT
(17) Measure ring gear backlash and check gear tooth contact pattern. Refer to Adjustments for pro- cedure.
(18) Install axle shafts. (19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N·m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N·m (24 ft.
lbs.).
DR
DIFFERENTIAL TRAC-RITE DESCRIPTION
The Trac-Rite™ differential is a helical gear differ- ential. The differential has two side gears, six pinion gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly only if damaged, but can be disassembled for cleaning. The assembly should be cleaned every time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on that side are forced toward the pinion brake shoes. The pinion brake shoes then cause frictional drag on the opposite pinion gears and the side gear. These friction forces transfer the power to the opposite wheel. Once the frictional forces are overcome, differ- entiation will occur. The torque will be continually biased by the frictional forces to the high traction wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts. (2) Remove differential case cover locating screws
(Fig. 38).
Fig.38LOCATIONSCREWS
1 - DIFFERENTIAL COVER 2 - LOCATION SCREWS
(3) Remove differential case cover. (4) Remove side gear and thrust washer (Fig. 39).
DR DIFFERENTIAL TRAC-RITE (Continued)
REAR AXLE - 10 1/2 AA
3 - 119
NOTE: Mark all component locations.
(6) Remove six pinion gears (Fig. 41).
Fig.39SIDEGEARANDTHRUSTWASHER
Fig.41PINIONGEARS
1 - SIDE GEAR 2 - THRUST WASHER
1 - PINION GEARS 2 - SIDE GEAR
(5) Remove three pinion brake shoes (Fig. 40).
Fig.40PINIONBRAKESHOES
1 - BRAKE SHOES 2 - PINION GEARS
(7) Remove remaining side gear thrust washer and
spacer.
(8) Remove remaining three pinion brake shoes.
CLEANING
Clean the differential case and gears with light oil
or a lint free cloth.
NOTE: Never use water, steam, kerosene or gaso- line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be smoothed with 400 grit emery cloth and polished out with crocus cloth.
(1) Inspect pinion gears teeth for chips and cracks
(2) Inspect pinion gears shafts and brake shoes for
scratches, flat-spots or worn (Fig. 42).
(3) Inspect side gears teeth for chips and cracks
(4) Inspect pinion and side gear bores for scratches
(Fig. 42).
(Fig. 43).
(Fig. 44).
NOTE: If any damage is found the differential must be replaced as an assembly. Individual components can not be replaced separately.
REAR AXLE - 10 1/2 AA
3 - 120
DIFFERENTIAL TRAC-RITE (Continued)DR
Fig.42PINIONGEARANDBRAKESHOE
1 - BRAKE SHOES 2 - PINION GEAR 3 - PINION SHAFT
Fig.44PINION/SIDEGEARBORE
1 - PINION BORES 2 - SIDE GEAR BORE
Fig.43SIDEGEARS
1 - THRUST WASHERS 2 - SPACER 3 - SIDE GEARS
ASSEMBLY
NOTE: Install all component in their original loca- tions.
(1) Lubricate all gears and differential bores with
differential lubricant.
case bores.
(2) Install one set of pinion brake shoes into the
Fig.45SIDEGEARANDSPACER
1 - SPACER 2 - SIDE SPACER
NOTE: Brake shoes can be installed upside down, but if install wrong pinion gear will not fit.
(3) Install side gear thrust washer, side gear and
spacer (Fig. 45).
(4) Install one set of pinion gears into the bores next to the brake shoes, with the pinion shaft facing up.
(5) Install other side gear and thrust washer.
DR DIFFERENTIAL TRAC-RITE (Continued)
REAR AXLE - 10 1/2 AA
3 - 121
(6) Install other set of pinion gears into the brake
shoes in the case.
gears shafts (Fig. 46).
(7) Install other set of brake shoes onto the pinion
Fig.46PINIONBRAKESHOES
1 - BRAKE SHOES 2 - PINION GEARS
(8) Install differential cover and location screws. (9) Install new ring gear bolts and tighten to 237
N·m (175 ft. lbs.).
DIFFERENTIAL CASE BEARINGS REMOVAL
(1) Remove differential case from the housing. (2) Install Plug 8888 into the end of the case. (3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 47).
INSTALLATION
(1) Install differenial case bearings with Installer
8956 and Handle C-4171 (Fig. 48).
(2) Install differentail case into housing.
Fig.47DIFFERENTIALCASEBEARING
1 - BRIDGE 2 - SPLITTER 3 - BEARING 4 - PLUG
Fig.48DIFFERENTIALCASEBEARINGS
1 - HANDLE 2 - DIFFERENTIAL CASE 3 - BEARING 4 - INSTALLER
3 - 122
REAR AXLE - 10 1/2 AA
DR
PINION GEAR/RING GEAR/ TONE RING REMOVAL
NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from axle housing. (4) Place differential on Plug 8888 and drive exciter ring off the differential case with a hammer and punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not being replaced.
Fig.50RINGGEAR
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flnage nut and washer.Fig.49EXCITERRING
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - PUNCH 4 - EXCITER RING
Fig.51FLANGEWRENCH
1 - PINION FLANGE 2 - FLANGE WRENCH
(5) Place differential case in a vise with soft metal
(6) Remove bolts holding ring gear to differential
jaw protectors
case.
(9) Remove pinion flange from the pinion with Pin-
ion Flange Puller 8992 (Fig. 52).
(10) Remove pinion gear from housing, with Pinion
Driver 8977 (Fig. 53) and a hammer.
DR PINION GEAR/RING GEAR/TONE RING (Continued)
REAR AXLE - 10 1/2 AA
3 - 123
Fig.52PINIONFLANGEPULLER
1 - PINION FLANGE 2 - PULLER
NOTE: Thread the driver on the pinion shaft till it bottoms out.
Fig.54REARPINIONBEARING
1 - PULLER 2 - VISE 3 - PINION SHAFT 4 - ADAPTER BLOCKS
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the if bearing is
housing with a punch and hammer, going to be replaced.
INSTALLATION
(1) Install new front pinion bearing cup (Fig. 55)
with Installer 8960 and Handle C-4171.
Fig.53PINIONDRIVER
1 - PINION SHAFT 2 - PINION DRIVER
(11) Remove pinion seal with a slide hammer or
pry bar.
shaft.
(12) Remove and discard front pinion bearing.
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove collapsible spacer from the pinion
(14) Remove rear pinion bearing with Puller
C-293-PA and Adapter Blocks 8879 (Fig. 54).
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the housing with a punch and hammer and discard cup.
Fig.55FRONTPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
REAR AXLE - 10 1/2 AA
3 - 124
PINION GEAR/RING GEAR/TONE RING (Continued)DR
(2) Install new rear pinion bearing cup (Fig. 56)
with Installer 8959 and Handle C-4171.
(4) Install rear pinion bearing (Fig. 58) with
Installer MD-998805 and a press.
Fig.56REARPINIONBEARINGCUP
1 - INSTALLER 2 - HANDLE
(3) Install pinion depth shim (Fig. 57) on the pin-
ion gear shaft.
Fig.58REARPINIONBEARING
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
(5) Install new collapsible spacer (Fig. 59).
Fig.57PINIONDEPTHSHIM
1 - PINION DEPTH SHIM 2 - PINION GEAR
Fig.59COLLAPSIBLESPACER
1 - COLAPSIBLE SPACER 2 - PINION GEAR 3 - REAR PINION BEARING
(6) Lubricate pinion and bearings.
DR PINION GEAR/RING GEAR/TONE RING (Continued)
(7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (Fig. 60).
REAR AXLE - 10 1/2 AA
3 - 125
Fig.60PINIONGEARINSTALLER
1 - INSTALLER 2 - DIFFERENTIAL HOUSING
(8) Install new pinion seal (Fig. 61) with Installer
8896 and Handle C-4171.
Fig.62FLANGEWRENCH
1 - FLANGE WRENCH 2 - PINION FLANGE
(14) Measure pinion rotating torque with an inch pound torque wrench (Fig. 63). Tighten pinion nut in small increments until pinion rotating torque is: † New Pinion Bearings: 1.7-2.8 N·m (15-25 in. lbs.)† Original Pinion Bearings: 1.1-2.2 N·m (10-20
in. lbs.)Fig.61PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold the pinion and lightly tap the pinion flange onto the pinion, until a few threads are show- ing.
(11) Install pinion flange washer and new pinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
(Fig. 62) and tighten pinion nut until pinion end play is taken up.(13) Rotate pinion several times to seat bearings.
Fig.63PINIONROTATINGTORQUE
1 - PINION FLANGE 2 - TORQUE WRENCH
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start two new ring gear bolts.
(17) Install the rest of the new ring gear bolts and
tighten them alternately to seat the ring gear.
REAR AXLE - 10 1/2 AA
3 - 126
PINION GEAR/RING GEAR/TONE RING (Continued)DR
(18) Torque ring gear bolts to 237 N·m (175 ft.
lbs.).
(19) If exciter ring was removed, position differen- tial assembly on differential Plug 8888 (Fig. 64) and place exciter ring on the differential case.
Fig.64EXCITERRING
1 - EXCITER RING 2 - RING GEAR 3 - DIFFERENTIAL PLUG 4 - DIFFERENTIAL CASE
(20) Install the exciter ring on the differential case evenly with a hammer and brass punch (Fig. 65). Drive the ring down until it is seated against the ring gear.
CAUTION: Do not damage exciter ring teeth during installation.
(21) Install differential into the housing.
Fig.65EXCITERRINGINSTALLATION
1 - EXCITER RING 2 - PUNSH 3 - RING GEAR
(22) Verify ring gear backlash and gear contact
pattern.
(23) Measure final rotating torque with an inch pound torque wrench. The final pinion rotating torque plus differential case bearing preload is: † New Bearings: 3.4-5.6 N·m (30-50 in. lbs.) † Original Bearings: 2.8-5.1 N·m (25-45 in. lbs.) (24) Install axle shafts. (25) Install the propeller shaft with the reference
marks aligned.
(26) Install differential cover with gasket and
tighten bolts to 40 N·m (30 ft. lbs.).
(27) Fill differential with fluid and tighten fill plug
to 32 N·m (24 ft. lbs.).
DR
REAR AXLE - 11 1/2 AA
3 - 127
REAR AXLE - 11 1/2 AA
TABLE OF CONTENTS
page
page
REAR AXLE - 11 1/2 AA
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 127
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 127
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 127
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 131
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 135
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 135AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138AXLE BEARINGS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 141
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 142
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144DIFFERENTIAL TRAC-RITE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 145
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 145
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 145
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 146
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 147DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 139REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 148PINION SEAL
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
