Ok, I've searched many different forums / read the FSM and I can't figure out / decipher my gear pattern. I replaced my trac lok clutch packs about 5000km ago and then got bearing noise so decided to replace all bearings / races. I have everything in and setup without crush sleeve and with previous shim on pinion. I have the pinion set to 25in/lb preload and the backlash set to .007" (on most teeth some are +/- .001/2 best I can get it). Now, my first problem is that when I rotate the the carrier forward with axle in and wheel on all sounds well, however if I rotate it in reverse I get a ticking sound. I am able to eliminate this noise by increasing the backlash but obviously that isn't a solution. Anyways attached are the most visible gear patterns I could photograph, to me it looks like the pinion is too deep, what do others think?

 

From the pictures I think you need a slightly thinner shim.

Ticking? I can't see it being from the teeth. I'd think it's a bearing problem.

 

Thanks for the reply. I too at first thought bearing. However wouldn't it make noise both directions ? This noise is only heard when reversing the carrier / axle. Here is a video of 2 forward revolutions and 2 reverse, the noise can be heard in reverse.

https://youtu.be/oVbAIrV0jf0

 

I hear it but can't place what it is.

 

Okay, I think I figured it out. I cranked the pinion up to approx. 200 foot pounds and then backed it off to achieve the proper preload. And then reset / re established .007 " backlash and the noise is 90% gone. And pattern is much better (in my opinion). Maybe the new races were not totally seated ? Causing the pinion to be deeper. ?

 

it's possible but i'd be worried about the crush sleeve and nut tension now. Unless you did that using the old crush sleeve?

 

I did it without any crush sleeve as per what I have read for setting up pinion depth. And it seems fine now so I will now put in the crush sleeve and set to spec. One confusion I have is in regard to crushing the sleeve. I have read that I should stop when I'm between 15 and 35 in/lb. But isn't it possible to achieve that without crushing the sleeve ? IE it would not be correct ?

 

on that I am not sure.

 

Well, today I put it all back together with a crush sleeve and seal initially torquing the pinion preload to about 25in/lb ( I say about because I am using bar type torque wrench not dial style). Setup my backlash again and boom noise is back and pattern looks like $@!#. Assuming I would either have to rip it all apart again and or change shims I attempted to slowly increase pinion preload to see if the noise went away. It did, however my preload is now too high approx. 45in/lb ( not breakaway but rather as much rotation as I can get with the small wrench on there).

Now, considering this is work truck with other problems... I very tempted to just leave it.

How long do we think the pinion bearing would last at the current preload? I am assuming the difference in used vs new bearing preload is due to some expected seating / wear? what are the odds my bearings wear themselves into spec? or conversely detonate very soon.

I know this probably sounds incredibly stupid and in most situations I would be a perfectionist, but I have seen quite a few threads where people literally set up the crush sleeve by 'feel' and seem to be fine...

Thoughts?

 

I would not do this work you need practice to get it correct I would pay to get this done by a specialty shop.

Expensive but worth it