Rev. A
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 at the tooths center and measure the differen-
tial pinion gear to side gear backlash (Fig. 35).
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. The drive side pattern should be lo-
cated at the toe portion of the tooth. The coast pattern
should also be at the toe portion of the tooth (Fig. 36).
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. Adjust side gear
shims as necessary. Recheck differential pinion gear to
side gear backlash.
10.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 35
1
2
3
Figure 36
DRIVE SIDE COAST SIDE
Heel
Toe
Heel
Toe
11.Install differential gear assembly in right side axle
support half.
12.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).
13.Install input shaft/pinion gear assembly (see Input
shaft/Pinion in this section of this manual).
14.Coat new O-rings with grease, align differential shaft
splines with differential gear assembly, and slide differ-
ential shaft assemblies onto axle support.
15.Install bevel gear case/axle case assemblies (see
Bevel Gear Case/Axle Case Assembly in this section of
this manual).
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