Front Differential Alignment Process (54/03/03/NAS)

ALIGNMENT FOR DIFFERENTIAL INSTALLATION REQUIRED

The required procedure for differential alignment during installation is not thoroughly covered in the RAVE Workshop Manual.

FOLLOW DIFFERENTIAL ALIGNMENT PROCESS

For component longevity it is important that the differential and the transfer box front output flange are correctly aligned. A process and a special measurement tool have been developed to ensure proper alignment of the transfer gearbox front output flange, propeller shaft and the front differential whenever work has been conducted on these components.

DIFFERENTIAL ALIGNMENT

1. Remove and discard the 'O' ring from the differential drive tube ('A' Fig 1 ).
   Fig 1: Removing 'O' Ring

   
   CAUTION: All grease must be removed.
2. Thoroughly clean the differential drive tube splines ('B' in Fig 1 ) and the propeller shaft splines.
3. Install the propeller shaft to the differential drive tube.
4. Slide the propeller shaft forwards and fit the centering flange ('A' in Fig 2 ) to the propeller shaft.
5. Temporarily secure the centering flange with a suitable nut and bolt. ('B' in Fig 2 )
   Fig 2: Securing The Centering Flange

   
6. Rotate the centering flange to allow the alignment tool to be placed in position (Fig 3 ).
7. Remove one slider from the alignment tool (LRT-54-032) and set aside.
8. Position the alignment tool into the bushing opening in the transfer gearbox front output flange. (Arrowed in Fig 3 )
   Fig 3: Positioning The Tool

   
9. Using a 2 mm Allen wrench, loosen the slider screw so that the slider moves freely along the rule.
   NOTE: It may be necessary to slide the propeller shaft, together with the alignment tool, slightly forwards. This will allow the alignment tool to be slightly extracted from the locating bush in the transfer gearbox front output flange, to allow clearance.
10. Slide the propeller shaft rearwards until the centering flange nipple is nearly in contact with the alignment tool surface. (Fig 4 ).
11. Position the alignment tool vertically with the slider below  the centering flange nipple.
12. Gently pull the propeller shaft down to its lowest position.
13. Tighten the slider screw to identify the extent of movement.
    NOTE: The alignment tool may have to be rotated into a horizontal position to note the measurement.
14. Record the measurement on the alignment tool, at the inside edge of the slider. (Insert Fig 4 ).
    Fig 4: Measuring

    
15. Loosen the slider screw so that the slider moves freely along the rule.
16. Position the alignment tool vertically with the slider above  the centering flange nipple.
17. Gently push the propeller shaft up to its highest position and move the slider down to the top of the centering flange nipple.
18. Tighten the slider screw using the Allen wrench.
    NOTE: The alignment tool may have to be rotated into a horizontal position to note the measurement.
19. Record the measurement on the alignment tool, at the inside edge of the slider. (Inset Fig 5 )
20. If the recorded measured distances above and below the locating bushing are equal within 1 mm  , the differential is correctly aligned to the transfer box front output flange. Go to section "Install Front Propeller Shaft".
21. If the measured distances are not equal within 1 mm  , go to section "Adjustment of Differential Alignment".
    Fig 5: Measuring Alignment

    

ADJUSTMENT OF DIFFERENTIAL ALIGNMENT

1. Slide the propeller shaft forwards, release the centering flange securing nut and bolt, rotate the centering flange and remove the alignment tool. (Fig 3 )
   Fig 6: Adjusting Alignment (1 of 2)

   
   NOTE: The calculated average measurement is the 'target' position (maximum up and down) for the propeller shaft in relation to the locating bushing in the transfer gearbox front output flange.
2. Calculate the average of the up and down recorded measurements to obtain the 'target' measurement.
3. Release the slider screw on the alignment tool and move the inside edge of the slider to the calculated 'target' position.
4. Fully tighten the slider screw with the Allen wrench.
   Fig 7: Adjusting Alignment (2 of 2)

   
5. Position the alignment tool into the transfer gearbox front output flange locating bushing. (Fig 8 ).
6. Rotate the centering flange into position and secure with a suitable nut and bolt.
7. Slide the propeller shaft rearwards until it contacts the face of the rule.
   Fig 8: Positioning The Tool

   
   NOTE: It may be necessary to slide the propeller shaft, together with the alignment tool, slightly forwards. This will allow the alignment tool to be slightly extracted from the locating bush in the transfer gearbox front output flange, to allow clearance.
8. If the measured distance was larger below  than above the centre line of the locating bushing, position the alignment tool vertically with the slider above  the centering flange nipple.
9. If the measured distance was larger above  than below the centre line of the locating bushing, position the alignment tool vertically with the slider below  the centering flange nipple.
   NOTE: The initial movement of the propeller shaft will be due to the fit of the propeller shaft and the drive tube mating splines. When approaching the slider, resistance will be felt as the differential moves.
10. Perform differential alignment as follows:
    • Release the four differential attachment bolts sufficiently to secure the differential, but still allow slight rotation on its axis. (Fig 9 )
    • Gently push the propeller shaft up or pull the propeller shaft down until the centering flange nipple touches the inside edge of the slider.
    • With assistance, hold the propeller shaft in this position and snugly tighten one of the differential bolts to secure the differential.
    • Verify the measurement above and below the centering flange nipple is equal and the same as the 'target' measurement.
    Fig 9: Differential Attachment Bolts

    
11. Repeat adjustments in step 10 up and down as required to achieve equal alignment measurements.
    CAUTION: A Torque wrench MUST be used when tightening the differential attachment bolts to 110 Nm (81 lbf.ft).
12. When the measurement is equal above and below the locating bush within 1mm of the 'target' position, tighten all bolts securing the front differential to 110 Nm (81 lbf.ft). 
13. Verify that the measurement above and below the centering flange nipple remain equal after the torque procedure.

PROPELLER SHAFT INSTALLATION PROCEDURE

1. Slide the propeller shaft forwards and remove the nut and bolt securing the centering flange to propeller shaft.
2. Remove the centering flange.
3. Remove the front propeller shaft.
   Fig 10: Installing Ring

   
   CAUTION: ONLY use grease TIA500010. Use of any other grease or lubricant will result in premature spline wear.
4. Lubricate the 'O' ring running surface with grease from packet (TIA500010).
5. Evenly distribute all of the remaining grease in the packet onto the propeller shaft splines and the drive tube splines.
6. Install the new 'O' ring (TYX000070) into the drive tube. (Fig 10 )
7. Install the propeller shaft into the differential drive tube.
8. Inspect the centering flange dust seal and install a new seal if indicated.
9. Clean the coupling and the centering flange mating faces.
10. Position the coupling and flange with the arrows on the coupling pointing towards the flange mounting. (Fig 11 )
11. Install bolts securing the coupling and tighten new nuts to 110 Nm (81 lbf.ft). 
12. Lower the vehicle onto its wheels.
13. Lower the lift.
14. Connect the battery ground cable.
    Fig 11: Festering Coupling And Flange