SERVICE MANUAL Make  certain  that  bearing  bores  are  clean  and  free of  nicks  and  burrs.    Adjust  micrometer  so  it  is  directly over end at a 90 deg.  angle to step plate. Run  micrometer  thimble  down  to  measure  distance between center of ring gear and step plate.  Make a note of this reading along with the nominal dimension given in "Specifications".    Locate  on  pinion  the  etched  marking which indicates variation from zero cone setting. If it is a minus figure, subtract it from specified dimension, and if a  plus  figure,  add  it  to  specified  dimension.    Results  of calculation   will   provide   the   corrected   pinion   nominal dimension  to  which  pinion  must  be  set.  Comparison  of corrected nominal dimension with the actual or measured-dimension indicates amount of change necessary    for    correct    pinion    position.        It    may    be necessary to add or remove shims between pinion cage and     diff     carrier     to     provide     correct     pinion     nominal dimension. Remove  gauge  and  prepare  to  install  ring  gear  and differential to diff carrier. Assemble Differential 1. If ring gear was removed from diff case, rivet gear to diff  case  flange.    Use  riveting  fixture  SE-2222  with hydraulic   press   (Fig.   32).      Rivet   pressures   (tons) should be within the range given in "Specifications". Fig. 32.  Installing Drive Gear to Diff Case 1 Riveting Fixture SE-2222 2 Press Ram 2. Apply rear axle lubricant to the inner walls of the diff case halves and to all differential component parts. 3. Place   side   gear   thrust   washer   and   side   gear   in flanged half of diff case and assemble spider, spider gears and spider gear thrust washers to side gear. 4. Place opposite side gear and thrust washer in other half of diff case. 5. Align  the  match  marks  and  assemble  the  diff  case. Draw   assembly   together   with   four   equally   spaced bolts  and  nuts.    Make  sure  side  gears  and  spider gears mesh correctly. 6. Check   for   free   rotation   of   side   gears   and   spider gears.  If satisfactory, install remaining diff case bolts and nuts. 7. Tighten  diff  case  bolt  nuts  to  specified  torque  (see "Torque Chart"). 8. Install  diff  bearings  by  pressing  them  squarely  onto diff case. Install Differential On Diff Carrier 1. Pre-lubricate   diff   bearings   with   rear   axle   lubricant and place bearing cups over bearings. 2. Lift  differential  assembly  and  place  into  position  in diff  carrier.    Tilt  differential  assembly  to  allow  ring gear to pass pinion pilot bearing. 3. Place bearing adjusters in carrier and turn hand tight against bearing cups. 4. Assemble  bearing  caps  to  carrier.    Align  identifying marks on bearing cap and carrier leg. 5. Install  bearing  cap  bolts  and  washers.    Tighten  to specified torque (see "Torque Chart"). 6. Tighten   bearing   adjusters   alternately   until   all   end play     is     eliminated.          Revolve     differential     while tightening bearing adjusters to correctly seat bearings. Set Gear Lash A special effort should be made to set the backlash between  pinion  and  ring  gear  to  the  same  amount  as was  originally  built  into  them  (.15-.3  mm  or  .006-.012"). Generally the amount of  backlash  is  stamped  or  etched on the ring gear.  When installing new gears, backlash is measured with a dial indicator mounted CTS-4044 PRINTED IN UNITED STATES OF AMERICA Page 18