General Procedures – Ring Gear Backlash Adjustment

Special Service Tools / General Equipment

	205-220 Installer, Differential Shim TKIT-1985-FX
Dial indicator
Copper hammer

Adjustment

1. 1
   Remove the differential carrier cover.
   REFER TO: Differential Carrier Cover (205-02 Rear Axle/Differential, Removal and Installation).
2. 2
   Install the dial indicator with the holder, with the dial indicator at 90 degrees to the ring gear tooth.
   Use general equipment: dial indicator

   

3. 3
   Using the dial indicator, check the ring gear backlash. Rotate the ring gear and carrier back and forth through the free play only. Maintain backlash of 0.127–0.229 mm (0.005–0.009 inch) with a maximum variation of 0.0762 mm (0.003 inch). Measure every 120º and take measurements at three different positions over 360º.
   REFER TO: Specifications (205-02 Rear Axle/Differential, Specifications).
   Use general equipment: dial indicator

   

4. 4
   • To correct high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.

   • If zero backlash condition exists, add 0.50 mm (0.020 inch) to the right shim and subtract 0.50 mm (0.020 inch) from the left shim to provide backlash indication. Recheck the backlash.

   • Using the backlash chart, determine the required differential shim thickness.
     REFER TO: Specifications (205-02 Rear Axle/Differential, Specifications).
5. 5
   1. Mark the differential bearing caps.

   2. Remove the differential bearing cap bolts.

   3. Remove the differential bearing caps.

   

6. 6
   Remove the differential case, differential case bearing cups and differential shims.

   

7. 7
   Install the differential case and differential case bearing cups.

   

8. 8
   1. Install the right-hand ring gear backlash adjusting shim.

   2. Position the differential assembly in the right-hand side of the differential housing. Install the right differential bearing cap and differential bearing cap bolts.

   

9. 9
   Using the special tool and a soft-faced copper hammer, install the left-hand ring gear backlash adjusting shim.
   Use special service tool: 205-220 Installer, differential shim.
   Use common equipment: soft-faced copper hammer.

   

10. 10
    Install the left differential bearing cap and differential bearing cap bolts.

    

11. 11
    Tighten the differential bearing cap bolts.
    Torque: 71 lb-ft (96 N·m)

    

12. 12
    Rotate the differential several times to make sure the differential assembly turns freely.

    

13. 13
    Using a dial indicator with a magnetic base, perform a final ring gear backlash check. Maintain 0.127-0.229 mm (0.005-0.009 in) backlash with a maximum runout of 0.0762 mm (0.003 in). Measure every 120° and take measurements at three different locations over 360°.
    Use common equipment: dial indicator

    

14. 14
    Check the ring gear tooth contact pattern for acceptability.
    Refer to: Rear Axle and Differential (205-02 Rear Drive Axle/Differential, Diagnosis and Testing).
15. 15
    Install the differential carrier cover.
    Refer to: Differential Carrier Cover (205-02 Rear Drive Axle/Differential, Removal and Installation).