Service Manual

Rev. E
Reelmaster 5200-D/5400-D4WD Rear Axle Page 9.1 - 20
(Unit Serial No. 200000001 & Up)
Installation
1. If the ring gear was removed, use medium strength
Loctite thread locker and tighten the mounting screws to
22 to 25 ft-lbs. (30 to 34 Nm).
2. Apply molybdenum disulfide to the splines and bear-
ing surfaces of the differential pinion gears, pinion wash-
ers, and side gears.
3. Install the side gear shims and side gears in their
original location in the differential case.
4. Place the differential pinion gears and pinion wash-
ers in their original location in the differential case. Tem-
porarily install the differential pinion shaft.
5. Secure the differential case in a vise. Position a dial
indicator on a tooth of the differential pinion gear. Press
the pinion and side gear against the differential case and
measure the pinion gear to side gear backlash (Fig. 36).
PINION GEAR TO SIDE GEAR BACKLASH:
0.004 to 0.016 in. (0.10 to 0.40 mm)
6. Adjust backlash by increasing or reducing side gear
shim thickness.
Note: Side gear shims are available in 0.043 in. (1.1
mm), 0.047 in. (1.2 mm), and 0.051 in. (1.3 mm) thick-
ness.
7. Paint the teeth of the differential pinion gears and
side gears with a gear marking compound, such as Dy-
Kem Steel Blue.
8. While applying a light load to either side gear, rotate
either pinion gear until the side gears have made one
complete revolution.
9. Ideal tooth contact should cover more than 35% of
each tooth surface. The contact area should be in the
center of each tooth and extent 1/3 to 1/2 way across
each tooth from the toe (small) end (Fig. 37).
10.Adjust side gear shims if necessary to correct tooth
contact. Recheck differential pinion gear to side gear
backlash if any changes are made.
11.After backlash and tooth contact have been ad-
justed, align the hole in the differential pinion shaft with
the hole in the differential case and install a new spring
pin.
1. Vise
2. Differential gear case
3. Dial indicator
Figure 36
1
2
3
Figure 37
More than 35% total tooth contact
1/3 to 1/2 of entire width
from small end of tooth
12.Install differential gear assembly in right side axle
support half.
13.Coat a new O-ring with grease and install left side
axle support half. Tighten axle support case screws to
35 to 41 ft-lbs. (47 to 56 Nm).
14.Install input shaft/pinion gear assembly (see Input
shaft/Pinion in this section of this manual).
15.Coat new O-rings with grease, align differential shaft
splines with differential gear assembly, and slide differ-
ential shaft assemblies onto axle support.
16.Install bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).