SERVICE MANUAL CLEANING, INSPECTION AND REPAIR Remove  all  dirt,  old  lubricant,  and  liquid  gasket material from components of the rear axle.    Immerse  in cleaning   solvent   and   use   a   stiff   brush   if   necessary. Bearings  should  be  cleaned  separately  in  clean  solvent and special efforts taken to protect their finely machined surfaces.    If  compressed  air  is  used  for  drying,  do  not spin bearings while drying. Examine  all  bearings  for  roughness,  damage  or wear  by  rotating  each  bearing  slowly  in  the  hand.    If  in doubt as to bearing condition, replace.  Ring gear, drive pinion, differential pinions and any other gears should be checked  for  damaged  teeth,  worn  spots,  or  distortion. Inspect    diff    case    assembly    for    cracks,    damage    or distortion.    Make  sure  splined  ends  of  axle  shafts  are neither   twisted   nor   cracked.      Shim   packs   should   be uniform  thickness.    Discard  thrust  washers  and  obtain new even when only slight wear is indicated. ADJUSTMENTS The    principal    adjustments    made    on    the    diff carrier assembly are devised for establishing  the  proper gear tooth contact and thereby obtaining a long wearing, quiet  running  rear  axle.    Fundamentally,  there  are  five adjustments  to  be  covered  and  these  are  accomplished as the diff carrier assembly is assembled.  To emphasize their   importance,   these   five   steps   or   adjustments   are listed here as well as in the actual assembly procedure. These adjustments are: 1. Preload the pinion bearings. 2. Set pinion nominal dimension. 3. Set gear lash. 4. Preload the diff bearings. 5. Check gear tooth contact. REASSEMBLY When reassembling the rear axles, see also the exploded  views  (Figs.  23  and  24)  for  correct  installation of parts. FORWARD REAR AND REAR AXLES Assemble Pinion and Cage 1. Place  rear  pinion  bearings  on  pinion  shaft  and press into place against pinion. 2. Place  pilot  bearing  on  stud  end  of  pinion  shaft and press firmly against shoulder of pinion.      Stake   face   of   pinion   shaft   in   six   (6) evenly  spaced  places  to  secure  pilot  bearing  in place (Fig. 25) Fig. 25.  Staking Pinion Pilot Bearing 1 Ground Face of Pinion 2 Metal Displaced to Secure Bearing 3 Blunt Point Punch 3. Pre-lubricate   the   bearings   with   rear   axle   gear lubricant. 4. Place  bearing  spacer  on  pinion  shaft  and  press against rear pinion bearing. IMPORTANT The  bearing  spacer  is  furnished  in  various thicknesses    in    graduations    of    .025    mm (.001”)     to     permit     changing     of     spacer thickness   to   obtain   correct   pinion   bearing preload. 5. Insert  pinion  (with  rear  pinion  bearing  and spacer) into pinion cage. 6. Mount pinion and cage in arbor press.  Place pre-lubricated front pinion bearing on pinion. 7. Press    bearing    into    place    firmly    against bearing preload spacer. 8. Revolve  pinion  cage  around  pinion  several times to seat bearings correctly. 9. Remove pinion and cage from press. CTS-4044 PRINTED IN UNITED STATES OF AMERICA Page 15