User Manual

ManualsBrandsYukon Gear ManualsAutomotiveYukon Gear & Axle (YC F3180-S) Standard Open Carrier Case & Spider Gear for Ford 31-Spline 8.8 Differential

Kit Installation Instructions

PLEASE READ COMPLETELY BEFORE INSTALLATION

his installation guide was written to provide the novice and professional with easy

guidelines for differential setup. Over the years we have gathered information from

Gleason gear design manuals, Dana Spicer instruction manuals, technical bulletins

and General Motors repair manuals. We have personally experienced good results using

the techniques in these instructions while setting up over forty thousand differentials.

Ring and pinion gears are designed to be set-up and run with exact tolerances. Replacing

all parts every time a differential is worked on is not only unnecessary, but is ridiculous.

However, any gear misalignment or deflection under load caused by worn or questionable

parts, can lead to early failure that can cost a lot more than the price of replacing them the

first time. Use your best judgment and remember that fixing your differential again, if it

fails, will take as much time and money as it did the first time.

We highly recommend Timken bearings and have used them for as long as we can

remember. We believe Timken bearings have held up best in all of the differentials we have

assembled or disassembled. We also recommend using only new or good used parts. New

parts are usually worth installing and save a lot of time and money that can be list by using

worn or questionable parts that lead to early failure.

We hope that these instructions are helpful and you will get years of use from your

differential.

Thank you Robert Hunt and Gregg Lloyd for your expert input and advice.

From all of us at Yukon Gear & Axle

Summary of content (11 pages)

PAGE 1
Kit Installation Instructions P LE AS E R E AD COM P LE TE LY B E FOR E I N STALL ATION T his installation guide was written to provide the novice and professional with easy guidelines for differential setup. Over the years we have gathered information from Gleason gear design manuals, Dana Spicer instruction manuals, technical bulletins and General Motors repair manuals.
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65 55 65 55 Note: Set up specifications are recommended only. Please call with questions. *Suggested starting points 12-15 .055 Samurai .067 .085 SUZUKI 7.5" F. or R. 8" F. or R. 8" Clamshell Front 9.5" Landcruiser 9.5" Tundra 10.5" Truck V6 R. T100 & Tacoma 50 100 75 60 90 90 90 75 100 63 120 200 Set-Up Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly . . . . . . . . . . . . . . . . . . . .
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TOOL LIST 1 2 DISASSEMBLY Disassembly 1. Ensure that you have everything you need before working. Verify whether all new parts match the application and parts invoice. 2. Lift the vehicle using an appropriate lift or jack, and support the vehicle with approved jack stands. Never work on an unsupported vehicle. 3. Drain used gear oil into a suitable container. We recycle our waste oil and request that you recycle yours, too. 4. Remove the axle shafts. 5.
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ASSEMBLY 3 3 ASSEMBLY Order of Adjustments Pinion Trial Assembly Differential assembly and setup adjustments include: 1. Pinion Depth 2. Pinion-Bearing Preload 3. Backlash 4. Carrier-Bearing Preload Assemble the pinion with its original shims yet without a crush sleeve to establish an approximate pinion depth. When installing the pinion, tighten the nut slowly until it reaches preload specifications.
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ASSEMBLY 3 Checking the Pattern We can determine how gears mesh by changing how close the pinion gear is to the ring gear centerline. While we can’t see how the gears actually relate to each other, we can coat their mating surfaces with gear-marking compound and read the patterns the gears create as they mesh. Genuine gear-marking compound offers a clear indication of gear contact without running or smearing.
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ASSEMBLY 3 Crush Sleeve Design Setting the pinion bearing preload in differentials that use a crush sleeve is relatively easy, although final assembly always requires a new crush sleeve. The crush sleeve permanently distorts, or crushes, at approximately 300 to 400 pounds/feet of torque on the pinion nut. Tighten the pinion nut until it exerts the optimum bearing preload, as measured by the pounds/inch torque wrench on the pinion nut.
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ASSEMBLY 3 n If the preload is close and the backlash is too loose, tighten the left adjuster a notch or two until the backlash is correct and the preload is sufficient. n If the preload is close and the backlash is too tight, tighten the right adjuster until the backlash is correct and the preload is sufficient. As stated before, ensure that the last adjustment made to the left adjuster tightens it. That will eliminate the possibility of a space between the adjuster and the bearing race.
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ACCEPTABLE PATTERNS Heel (Outer end) 6 Heel (Outer end) Coast Drive Heel (Outer end) Heel (Outer end) Drive Toe (Inner end) Toe (Inner end) Heel (Outer end) Coast Coast Drive Kit Installation Manual Coast Drive Toe (Inner end) Toe (Inner end) Kit Installation Manual Coast Drive Heel (Outer end) Drive Toe (Inner end) Heel (Outer end) Drive Heel (Outer end) Toe (Inner end) Coast Toe (Inner end) Coast Drive Heel (Outer end) Drive Coast Toe (Inner end) Coast Toe (Inner end) 14
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PINION IS TOO FAR AWAY 8 Coast Coast Drive Drive Toe (Inner end) Toe (Inner end) Heel (Outer end) Heel (Outer end) Coast INSTRUCTIONS SUMMARY Checking Backlash Heel (Outer end) Heel (Outer end) 9 Coast Backlash is the free movement of the ring gear with the pinion gear fixed in place. All ring and pinion sets are matched pairs. Make sure you have a matched ring and pinion set. Clean all parts before you start assembly. Apply a light coat of oil to all bearings.
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INSTRUCTIONS SUMMARY 9 Pattern Movements Summarized 1. Move the ring gear closer to the pinion to decrease backlash. 2. Move the ring gear farther from the pinion gear to increase backlash. 3. Move the pinion closer to the ring gear to move the drive the pattern deeper on the tooth (flank contact) and slightly toward the toe. The coast pattern will move deeper on the tooth and slightly toward the heel. 4.
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Warranty Details Y ukon Gear & Axle® (“Yukon”) warrants the original retail purchaser that all Yukon products will be free from defects in materials and workmanship for the warranty period (see website for details). Yukon makes no other warranty of any kind, express or implied. All other warranties, including but not limited to an implied warranty of merchantability or fitness for a particular purpose, are excluded.