Service Manual

5. Determine necessary quantity of support shims.
A. Lubricate the axle case support bushing with a
thin coat of grease and slide axle case support onto
knuckle
pin.
B. Position support shims that were removed during
disassembly
between axle case support and axle
case. Install mounting screws into axle case. Slowly
tighten screws while frequently checking for clear-
ance (vertical endplay) between axle case support
and knuckle pin. If binding of components is noted
before screws are fully tightened, add additional sup-
port shims. Torque screws from 57 to 67 ft–lb (77 to
91 N–m).
C. Use dial indicator to measure vertical endplay of
axle case (Fig. 8).
AXLE CASE ASSEMBLY ENDPLAY:
0.001 to 0.008 in. (0.02 to 0.20 mm)
D. Adjust endplay by increasing or reducing number
of axle case support shims.
NOTE: Axle
case support shims are available in
0.004 in. (0.1 mm), 0.008 in. (0.2 mm), and 0.016 in.
(0.4 mm) thickness.
6. After correct support shims have been determined,
remove
mounting screws, apply heavy strength thread–
locking compound to screw threads, reinstall screws,
and torque from 57 to 67 ft–lb (77 to 91 N–m).
IMPORTANT: Correct engagement between bevel
gears is critical to axle performance and durability
.
7. Temporarily install the bevel gear case/axle case as-
sembly on the axle support. Position a dial indicator at
the tooths center
. Prevent the axle from turning and
measure the upper bevel gear to differential shaft gear
backlash (Fig. 9).
UPPER BEVEL GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
8. Adjust backlash by increasing or reducing axle bear-
ing shim thickness (see Differential Shafts
in this section
of this manual).
NOTE: Axle
bearing shims are available in 0.004 in.
(0.1 mm), 0.008 in. (0.2 mm), and 0.020 in. (0.5 mm)
thickness.
1
2
4
5
3
6
VERTICAL
(77 to 91 N–m)
ENDPLAY
57 to 67 ft–lb
Figure 8
1. Axle case support 4. Dial indicator
2. Axle case 5. Knuckle
pin
3. Bevel gearcase 6.
Support shim location
1
2
3
4
5
Figure 9
1. Axle support 4. Dial indicator
2. Upper bevel gear 5.
Axle bearing shims
3. Differential shaft gear
4
5
1
3
2
Figure 10
1. Axle cover assembly 4. Dial indicator
2. Lower bevel gear 5.
Axle bearing shims
3. Axle gear
4WD Rear Axle Page 10.1 – 6 Groundsmaster 228–D
(Groundsmaster 228–D with Dae Dong axle)
Rev. E