Diff setup

Bretto · Post by **Bretto** » Wed Feb 23, 2011 10:33 pm

So I'm setting up my diff with the same gear set that was in there but with new carrier bearings. Shouldn't I be able to get a really good pattern being they are used but are from the housing they came from? I started with the previous shim thickness but the pattern isn't making me happy. I have tried adjusting a little here and there. Should I just try to get a good pattern on the coast side and run with it?
Thanks guys.

GPA · Post by **GPA** » Thu Feb 24, 2011 6:20 am

You should aim for correct pattern on both coast and drive side. If not, it will have whining sound and wear quickly.

idiocrates · Post by **idiocrates** » Thu Feb 24, 2011 8:35 am

Rebuilding the dana 44 rear axle on this a-1 was hands down the most difficult task I have undertaken during my repairs. My old ring and pinion set were completely worn out so I had to start over completely with a new gear set, new bearing cones, new races, and new shims. And of course I had no setup tools....just a dial indicator and a micrometer....and towards the end....some prussian blue....which thank goodness....Grainger still feels compelled to carry. Oh yeah.....and I purchased an extra set of carrier bearings which I carefully honed out with a brake cylinder hone in order to make them slip fits on the carrier so I could readily adjust carrier position. I started with the numbers on the old ring set.....compared them to the numbers on the new ring set.....did the math....measured the existing shims....and adjusted the stack accordingly. Installed the pinion.....got the preload just right....installed the carrier.....did a pattern check......and it looked awful. After that it was all down hill. Pulled everything back out and repeated this process at least a dozen times until the pattern I wound up with looked pretty darn close to some I found on the Internet. Personally....I think mine looked better then theirs....but hey, after all the time (and ruined shims)it took to get there...it HAD to look better...right? Its a tedious task and one you do not want to get rushed on....just hang in there....it will eventually come together....even if it is just a place only you can live with. I only hope my setup gives close to half a century of service like the old one did.

Bretto · Post by **Bretto** » Thu Feb 24, 2011 9:40 am

Ive done 2 axles before this on used gear sets and got them set fine. The only hard part (to me) is changing the pinion depth in that you have to pull everything off and pound out that darn inner race. I ruin shims everytime. In fact I have to go buy some more today. I've got the carrier bearing removal process down pat. I dont like having to pull them off but its not hard anymore now that I have my own procedure.
I just figured that using the existing gear set that was already in the case, it would of dialed in faster than it is taking.
By the way you can just go to a craft store and buy prussian blue oil paint. I also like yellow. In fact I had found that on my previous adventure of axle rebuilds I liked the blue over yellow, but this time around I was just not getting a good indication of the pattern on the coast side until I decided to try some yellow. It lit it right up. I guess it was actually green since they mixed but it made a world of difference on showing the pattern.