Diff Rebuilding

[rob83ke70]

hey

rebuilding a borgwarner ke55 diff, put all new bearings in it, put another carrier/crownwheel/pinion assembly (4.3 out of ke70) into it, old one was a 4.11. played around with the shims I have (not many) but I'm a bit lost. I get to do a lot of services at work and not a great deal of rebuilding and repairing, probably more replacing than anything else.

 

Apparently I'm supposed to use a 20 thou shim if I'm reusing the collapsible spacer. When I put the shim in, I can't seem to get enough preload on the pinion bearings, and the backlash is a bit much. Without the shim, I have good backlash, and maybe only JUST enough preload...

 

My drama is that after it has all been put together, then disassembled and put back together again, I have noise under drive and noise under overdrive with some chattering type noise on coast. It would have to be the crownwheel/pinion gears making the noise, and I figure they would have to be adjusted wrong, but the question is how do I adjust it correctly? I was enlightened AFTER I put it together tonight as to the trick to making the pretty patterns with the bearing blue, you need to use a prybar or similar to put load on the carrier when you turn the pinion thus creating nice patterns. I had all the trouble in the world making patterns and more or less gave up on the patterns. Not like I have any spare shims to play with anyway.

 

Anybody with spare shims??

 

Any ideas as to what I'm doing wrong?

 

This really really irks me because I'm a mechanic, but I don't get to rebuild diffs and gearboxes and all those fun things. I can hardly remember the brief bit on diffs we did at tafe as an apprentice. Yes you can all laugh at me now!

 

I'm going to dig up something nerdy like trigonometry now so I can stop thinking about the damn diff noise.

 

Robert.

[rob83ke70]

I think I have insufficient preload on the pinion bearings and I need to shim the bearings outwards to get this right.

 

Anyone got any spare shims for borgwarner diffs???

 

Robert.

[corollaart]

I m no expert at it but it sounds like lack of preload .According to mr gregory pinion preload as follows

 

New bearings with seal 1.7_ 3.4 Nm

 

Uesd bearings with seal 1.7-2.8 Nm

 

If collapisble spacer is used for a second time a 0.76 shim must be used.

 

don't no if thats any help or not ,good luck

[rob83ke70]

I'm missing a shim or don't have a thick enough shim on the pinion bearings, thus when the nut is tightened all the way up I don't have preload..... I will try to get some shims and goodies and have another go sometime this week.

 

Robert.