TM 5-3810-300-24 & P2
When assembling component parts use a press where possible.
Tighten all the nuts to the specified torque. (See torque limits following service instructions). Use soft iron locking
wire to prevent possibility of wire breakage.
The burrs, caused by lockwashers, at the spot face of stud holes of cages and covers should be removed to assure
easy reassembly of these parts.
SEE TABLE 4-1 FOR TORQUE VALUES TO BE USED DURING REASSEMBLY.
Assemble Hypoid Pinion.
Press the rear cone squarely and firmly against the
pinion head. Use a suitable sleeve that will bear
against cone race.
Prior to assembling the rear bearing cup, spacer and shim pack (install gear spacer if used), note following: If
original gears and rear bearings are reused, install original shim pack. If gears have been replaced, alter the original
shim pack as follows: Note the variation from the nominal assembly dimension on both the old and new pinion.
(The nominal dimension is stamped and the variation is etched on the "nose" of the pinion). Increase or reduce the
shim pack in accordance with the change in the variation from the old to the new pinion. After changing the sign of
the old variation plus to minus or minus to plus add to the new variation (sign unchanged). The answer will be
increase or decrease of the original shim pack in thousandths of an inch.
Old Pinion Marked
New Pinion Marked
3.125 + 6
3.125 + 2
First, we change the sign of the variation of the old pinion (+) which changes the variation from +6 to -6. Then we add -6
to the variation of the new pinion, +2, which gives us an answer of -4. This means that we must add .004" from the shim
pack used with the old pinion.
C. Install rear bearing cup against the shim pack (and spacer, if used).
D. Install the outer pinion bearing cup to bottom in cup bore.
E. Lubricate bearing and cups with light machine oil.
F. Place the carrier and cap under a press, carrier legs down. Hold transfer _ gear in position and thread pinion shaft
up through inner bearing cup and