Weber State University (WSU) - Automotive Technology Department - Transmission Lab. We are finally done with the overhaul and restoration of the rear differential of a 1963 Chevrolet Biscayne. This 8.2" type 3 differential was used by General Motors from 1955-1964. The differential design utilizes threaded adjustable side bearing spacers to control side bearing preload and backlash.

This video shows the proper reassembly procedures including setting bearing preloads, setting backlash, and reading the contact pattern. Download our Ring Gear Contact Pattern Interpretation Guide at http://departments.weber.edu/automoti...

Timeline:
0:00 Introduction
1:00:34 Install Crush Sleeve
1:01:06 Install front pinion bearing and seal
1:06:36 Install pinion gear into the axle housing
1:16:00 Pinion Flange holding tool
1:24:36 Torque Multiplier usage
1:28:00 Tightening the pinion nut to crush the crush sleeve
1:33:50 Pinion bearing preload is finally starting
1:34:20 Consequences of high bearing preload, take baby steps.
1:35:12 Pinion bearing preload too low; tighten more
1:37:50 Pinion bearing preload within specifications
1:39:00 Install the differential case with the ring gear


See parts 1, 2, 3, 3.1, and 3.2 videos for disassembly and inspection procedures.

This video helps satisfy the requirements of the following NATEF tasks - 3.E.E1:
1.     Clean and inspect differential housing; check for leaks; inspect the housing vent.
2.     Check and adjust the differential housing fluid level.
3.     Drain and refill differential housing.
4.     Diagnose noise and vibration concerns; determine necessary action.
5.     Inspect and replace companion flange and pinion seal; measure companion flange runout.
6. Inspect ring gear and measure runout; determine necessary action.
7. Remove, inspect, and reinstall drive pinion and ring gear, spacers, sleeves, and bearings.
8. Measure and adjust drive pinion depth.
9. Measure and adjust drive pinion bearing preload.
10. Measure and adjust side bearing preload and ring and pinion gear total backlash and backlash variation on a differential carrier assembly (threaded cup or shim types).
11. Check ring and pinion tooth contact patterns; perform necessary action.
12. Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case.
13. Reassemble and reinstall differential case assembly; measure runout; determine necessary action.

Questions:
1. Why should a new pinion nut always be used?
2. What problem can occur when installing a pinion seal?
3. Why are the splines of the pinion gear supposed to be coated with Teflon sealant?
4. Why, when installing the pinion gear into the front pinion bearing, does the pinion gear not just slide inside the bearing. In other words, why must the bearing be pressed or tapped down slightly before installing the pinion flange?
5. Google "Bearing Brinnelling" What can cause bearing brinelling?
6. Why does there need to be endplay in the front bearing when installing it?
7. Google the datasheet for Loctite 271 thread-lock compound. How many hours are required before the liquid thread-lock is fully cured?
8. What is the purpose of the blue pinion flange holding tool?
9. How much torque is required to start crushing a crush sleeve?
10. How much torque must be applied to a 4:1 torque multiplier to obtain 350 lb*ft of torque (assuming a 20% frictional loss)?
11. If you still have up and down endplay in the pinion gear, are you preloading the bearings or are you still crushing the crush sleeve?
12. How can you tell if you are actually preloading the pinion bearings?
13. Why should you always rotate preloaded bearings a few times before measuring their actual preload?
14. What should you do if you apply too much preload to the pinion bearings (on an axle with a crush sleeve)?
15. What do I mean by taking "baby steps" in the video?

http://www.weber.edu/automotive

This video was created and edited by John D. Kelly at WSU. For a full biography, see http://www.weber.edu/automotive/J_Kel...

Visit my other youtube channel    / vibratesoftware   to see the amazing NVH app for vibration diagnosis!

Donate to the Department of Automotive Technology at Weber State University here: http://advancement.weber.edu/Automotive