SERVICE MANUAL Establish Inter-Axle Diff-To-Cover (Now Cone) End Play Diff case-to-cover (nose cone) end play is controlled by  shims  placed  between  the  front  bearing  and  the  diff cover,  as  shown  in  Fig.  40.    The  instructions  below  tell how   to   determine   the   thickness   of   shims   required   to keep end play within specified limits. The    following    instructions    show    the    intermediate case  removed  from  the  diff  carrier;  however,  a  similar procedure    can    be    followed    to    determine    the    shim thickness while the intermediate case is mounted on the diff carrier.  Be careful to prevent differential from falling to avoid personal injury or damage to parts. Fig. 40.  Cross-Section Showing Shims Used To Control Inter-Axle Diff End Play 1 Intermediate Case 2 Snap Ring 3 Rear Bearing 4 Inter-Axle Differential 5 Cover 6 Front Bearing 7 Shims 1. Position  diff  case  in  intermediate  case  by  inserting rear bearing into bearing bore of intermediate case. Tap  on  end  of  input  shaft  with  a  fiber  or  plastic hammer  (do  not  use  soft  metal  hammer)  to  seat rear  bearing  snap  ring  firmly  against  intermediate case. 2. Assemble  diff  cover  to  diff  case.    Do  not   include shims, diff cover gasket, or diff cover oil seal.  Tap cover   with   a   soft   hammer   to   seat   cover   firmly against intermediate case. 3. Using  a  feeler  gauge,  measure  clearance  between front bearing and cover.  This clearance represents the  total  amount  of  case-to-cover  end  play.    Note and record this amount. 4. To   determine   the   thickness   of   shims   required   to obtain the specified end play, subtract the amount of permissible  end  play  .00-.12  mm  (.000-.005")  from the   total   end   play   found   in   step   3   above.      For Example: Total End Play (per step 3)  .70 mm (.028") Minus Specified End Play   .000-.12 mm (.000-.005") Leaves Required Shim .58-.70 mm Thickness Range of  .  .  .   (.023-.028") Shims are furnished in thicknesses of .13 to .25 mm  (.005  and  .010").    Select  a  shim  pack  with  a  total thickness  within  the  range  of  required  thickness  found above. Two .25 mm (.010") shims plus one .13 mm (.005") shim total .  .  .  .  .  .  .  . 63 mm (.025") Which is within the required thickness range of.  .  .  .  58-.70 mm (.023-.028") Thus: Total End Play (per step 3)   .70 mm (.028") Minus Thickness of Shim Pack   .63 mm (.025") Leaves Final End Play of .07 mm (.003") and is within the specified limits of .000-.12 mm (.000-.005")  .  .  .  .  .  .  .07 mm  (.003") 5. Remove    the    differential    cover    from    intermediate case and position shim pack (as determined above) between front bearing and cover (Fig. 41). 6. Replace   cover   on   intermediate   case   making   sure shims    are    centered    on    bearing    race    to    avoid pinching shims between cover and O.D. of bearing. Tap  cover  with  a  soft  hammer  to  seat  cover  firmly against intermediate case. 7. Check end play by measuring clearance between the shims and the cover.  Clearance (end play)  should be within specified limits. While  .000  end  play  is  permissible,  it  is  important that  the  bearings  not  be  loaded  with  side  thrust. Therefore,   end   play   between   specified   limits   is desired. CTS-4044 PRINTED IN UNITED STATES OF AMERICA Page 22