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
