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Morris, excellent advice on how to solve Aarons one minor snag. Really is a pretty simple fix Aaron, dont let it slow ya down!
Sherm, good tools is always a must! Sounds like your like the rest of us though, try to get away with out the proper tool first, then find out ya need to redo it with the tool haha. Been there a few times!
Morning...Well I got ambitious last night and pulled the car apart again, got the rear end on the bench for the 2nd time. The three things I suspected were wrong are wrong. We had backlash set too tight, it was at 0.005", when spec is between 0.008"-0.015", ideal setting is between 0.012"-0.015". Our pinion depth was too shallow causing the pinion to run on the heel of the ring gear, more shims needed to bring it more to the center of the ring gear. Lastly was the preload on the new pinion bearing. It should only be 16-29 inlbs, I'd say we were closer to 50 inlbs of rotating torque. One needs a "dial" type of torque wrench, a "click" style won't work.
So with all that said and done, I need to get another inner pinion bearing cause I wrecked one pulling it off the pinion with a chisel. I've got new shims, and I know how much I need to move the carrier to get the proper backlash... Perhaps some more ambition tonight and we'll be rolling successfully again...
yup...just one more tool...lol... I think a person should be able to guage the rolling resistance of the pinion bearing... it should spin by hand with a little effort, not free wheel, but not have to grunt to spin it...