Rev. A
Reelmaster 5200-D/5400-DDifferential Axle Page 6 - 20
8. Install the outer pinion spacer with the chamfer to-
wards the pinion splines and position the new outer
bearing cone on the pinion shaft (Fig. 44).
Figure 44
9. With a hollow press sleeve of proper diameter, press
on the outer bearing cone race until the drive pinion
seats in the carrier and a slight drag is felt when the gear
is rotated by hand (Fig. 45). If more than 2-13 in-lb.
(.2-1.5 Nm) torque is required to rotate the pinion and
spur gear, tap the pinion shaft with a soft mallet until the
drag is reduced.
10.Install the shim, pinion coupler, spacer, and nut onto
the end of the pinion shaft. Tighten pinion coupler nut to
75 to 90 ft-lbs (100 to 122 Nm). Check pinion shaft end-
play and adjust if necessary.
PINION SHAFT END PLAY:
0.000 to 0.005 in. (0.00 to 0.13 mm)
Note: Pinion shaft shims are available in 0.094 in.
(2.39 mm) to 0.120 in. (3.05 mm) thickness, and in
0.125 in. (3.18 mm) to 0.151 in. (3.84 mm) thickness in
0.002 (0.05 mm) increments.
11.Install pinion coupler cover (2WD units).
12.Install the spur gear cover. Use Permatex No. 2 or sil-
icone sealant when installing the cover. Tighten the
capscrews to a torque of 25-40 in.-lb. (3-4.5 Nm)
(Fig. 46).
Figure 45
Figure 46
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