Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

PINION DEPTH-BEARING PRELOAD-GEAR BACKLASH

Ring and pinion gears are supplied as matched set. The
identifying match numbers (3) for the ring and pinion
gear are etched into the face of each gear. A plus (+)
number, minus (–) number or zero (0) is etched into the
face of the pinion gear (2). This number is the amount
(in thousandths of an inch) the depth varies from the
standard depth setting of a pinion etched with a (0).
The standard depth provides the best teeth contact
pattern. Refer to Backlash and Contact Pattern Analysis
Paragraph in this section for additional information.

Compensation for pinion depth variance is achieved

with select shims. The shims are placed under the inner
pinion bearing on the pinion shaft.

If a new gear set is being installed, note the depth variance etched into both the original and
replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate for
the difference in the depth variances. Refer to the Depth Variance charts.

Note where Old and New Pinion Marking columns intersect. The intersecting figure represents plus or
minus the amount needed.

Note the etched number on the face of the drive pinion gear (–1, –2, 0, +1, +2, etc.). The numbers
represent thousands of an inch deviation from the standard. If the number is negative, add that value
to the required thickness of the depth shim(s). If the number is positive, subtract that value from the
thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the Pinion Gear
Depth Variance Chart.

Note: This procedure is for training purposes only. Always refer to the Page 1 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

PINION GEAR DEPTH VARIANCE

Original Replacement Pinion Gear Depth Variance

Pinion
Gear
-4 -3 -2 -1 0 +1 +2 +3 +4
Depth
Variance
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

PINION DEPTH MEASUREMENT

Measurements are taken with pinion cups
and pinion bearings installed in housing. Take
measurements with Pinion Gauge Set 6730
(2,3,4,5,6,7,8) and Dial Indicator C-3339A (1).

Note: This procedure is for training purposes only. Always refer to the Page 2 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

1. Assemble Pinion Height Block 6739 (2),

Pinion Block 9990 (1) and rear pinion
bearing onto Screw 6741.
2. Insert assembled height gauge components,
rear bearing and screw into axle housing
through pinion bearing cups.
3. Install front pinion bearing and Cone Nut
6740. Tighten nut until torque to rotate the
screw is 2.25 N·m (20 in. lbs.). Measure
torque to rotate with an inch pound torque
wrench.

4. Place Arbor Disc 8541A (1) on Arbor D-115-

3 (2) and position in the housing side
bearing cradles.
NOTE: Arbor Discs 8541A have different
step diameters to fit other axle sizes.
Pick correct size step for axle being
serviced.

5. Install differential bearing caps (1) on arbor

discs (2) and tighten cap bolts to 108 N·m
(80 ft. lbs.).

Note: This procedure is for training purposes only. Always refer to the Page 3 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

6. Assemble Dial Indicator C-3339A (1) into

Scooter Block D-115-2 (2) and secure set
screw.
7. Place Scooter Block/Dial Indicator in
position in axle housing so dial probe and
scooter block are flush against the rearward
surface of the pinion height block. Hold
scooter block in place and zero the dial
indicator face to the pointer. Tighten dial
indicator face lock screw.
8. Slowly slide the Scooter Block/Dial Indicator
across the pinion height block over to the
arbor bar (1). Move the Scooter Block/Dial
Indicator to the crest of the arbor bar and
record the highest reading.
9. Select a shim equal to the dial indicator
reading plus or minus the pinion gear depth
variance number etched in the face of the
pinion gear.
Example: If the depth variance is – 2 add
0.002 in. to the dial indicator reading. If the
depth variance is + 2 subtract 0.002 in. to
the dial indicator reading.

The total is the shim thickness needed for

the pinion depth variance.

PRELOAD SHIM SELECTION

Before performing differential bearing preload and ring
gear backlash measurements, pinion gear depth must
be established and the pinion gear ready for installation.
Establishing pinion gear depth is essential to gear
backlash and tooth contact patterns.

Differential side bearing preload and gear backlash is

accomplish with selective shims (2,4) positioned behind
the differential side bearing cups. Shim thickness is
determined using Dummy Bearings 9992 in place of the
differential side bearings and a Dial Indicator C-3339A.

SHIM FORMULA : Differential End Play + Preload

Specification = Total Differential Shim. Total Differential Shim – Ring Gear Side Shim – Backlash
Specification = Pinon Gear Side Shim.

Note: This procedure is for training purposes only. Always refer to the Page 4 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

1. Remove differential side bearings from

differential case.
2. Remove factory installed shims from
differential case.
3. Install ring gear on differential case and
tighten bolts to specification.
4. Install dummy side bearings 9992 (1) on
differential case.
5. Install differential case (3) with dummy
bearings (1) into the differential housing (2).

6. Install the differential (3) bearing caps (1) in

their correct positions. Install and snug the
bolts.

7. Seat pinion gear side (2) differential dummy

bearing in the housing with a dead blow
hammer (1).

Note: This procedure is for training purposes only. Always refer to the Page 5 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

8. Seat ring gear side (1) differential dummy

bearing in the housing with a dead blow
hammer (2).

9. Install Pin C-3288-B (3) into rear cover bolt

hole below ring gear.
10. Attach a dial indicator C-3339A (4) to Pilot
Stud C-3288-B (3). Position the dial indicator
plunger on a flat surface between the ring
gear bolt heads.

Note: This procedure is for training purposes only. Always refer to the Page 6 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

11. Push and hold differential case (1) to pinion

gear side of the housing and zero dial
indicator (2).

12. Push and hold differential case (2) to

ring gear side of the housing. Record
dial indicator (1) differential reading. Add
preload specification 0.25 mm (0.010 in.) to
differential dial indicator reading. This is the
total shim needed to preload the differential
bearings.
EXAMPLE: Differential Dial Indicator
Reading + Preload Specification 0.25 mm
(0.010 in.) = Total Differential Shim
13. Rotate dial indicator out of the way on pilot
stud.
14. Remove differential case and dummy
bearings from the housing.
15. Install pinion gear in the housing and
establish pinion torque to rotating (PTTR).

Note: This procedure is for training purposes only. Always refer to the Page 7 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

16. Install differential case and dummy bearings

9992 in the housing, install bearing caps and
tighten bolts snug.
17. Seat ring gear side (3) dummy bearing in the
housing (1) with dead blow hammer (2).

18. Position the dial indicator plunger (4) on

a flat surface between the ring gear bolt
heads.

Note: This procedure is for training purposes only. Always refer to the Page 8 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

19. Push and hold differential case (1) toward

the pinion gear and zero dial indicator (2).

20. Push and hold differential case (2) to ring

gear side of the housing and record dial
indicator (1) ring gear side reading.
21. Subtract backlash specification 0.05 mm
(0.002 in.) from ring gear side reading for
ring gear backlash. The remainder is the
shim needed on the ring gear side of the
differential.
EXAMPLE: Ring Gear Side Dial Indicator
Reading – Backlash Specification 0.05 mm
(0.002 in.) = Ring Gear Side Shim
22. Subtract ring gear side shim from differential
total preload shim. This remainder is the
shim needed on the pinion side of the
differential.
EXAMPLE: Total Differential Shim – Ring
Gear Side Shim = Pinion Gear Side Shim
23. Rotate dial indicator out of the way on pilot
stud.
24. Remove differential case and dummy
bearings from the housing.
25. Install new side bearings on differential
case.

Note: This procedure is for training purposes only. Always refer to the Page 9 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

26. CAUTION: Never spread housing over

0.50 mm (0.020 in). Failure to follow these
instructions will damage the housing.
Install Spreader W-129-B (1) with hold
downs (2) from Adapter Set 6987B on
the housing and spread open enough to
receive differential case.

27. Install differential case (2) into the housing

with bearing cups (3) and shims.

28. Install bearing caps and tighten bolts finger

tight. Remove spreader from the housing.
29. Install bearing cap (1) and tighten bolts to
108 N·m (80 ft. lbs.).
30. Rotate the differential case several times to
seat the side bearings.

Note: This procedure is for training purposes only. Always refer to the Page 10 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

31. Position dial indicator (1) plunger against a

ring gear tooth.
32. Push and hold ring gear upward while not
allowing the pinion gear to rotate and zero
dial indicator.
33. Push and hold ring gear downward while
not allowing the pinion gear to rotate. Dial
indicator reading should be between 0.12
mm - 0.20 mm (0.005 in. - 0.008 in.).

If backlash is not within specifications transfer

the necessary amount of shim thickness from
one side of the housing to the other

Verify differential case and ring gear runout

by measuring ring to pinion gear backlash at
eight locations around the ring gear. Readings
should not vary more than 0.05 mm (0.002 in.). If
readings vary more than specified, the ring gear
or the differential case is defective.

After the proper backlash is achieved, perform

Gear Contact Pattern Analysis procedure.

GEAR CONTACT PATTERN

The ring gear and pinion teeth contact patterns will
show if the pinion depth is correct in the housing.
It will also show if the ring gear backlash has been
adjusted correctly. The backlash can be adjusted within
specifications to achieve desired tooth contact patterns.

The TOP LAND (1) of the gear tooth is the top surface
of the tooth. The PROFILE (2) of the gear tooth is the
depth of the tooth. The TOE (3) of the gear is the portion
of the tooth surface at the end towards the center. The
HEEL (4) of the gear is the portion of the tooth at the
outer-end. The ROOT (5) of the gear tooth is the lowest
portion of the tooth.

Note: This procedure is for training purposes only. Always refer to the Page 11 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure
NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE
across the tooth is tapered it is a 2 Axis cut gear.

1. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear
teeth.
2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of
the pinion. This will provide a more distinct contact pattern.
3. Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete
revolution in both directions while a load is being applied from shop towel.

The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will
squeegee the compound to the areas with the least amount of contact. Note and compare patterns on
the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash
as necessary.

THREE AXIS CUT GEARS

Note: This procedure is for training purposes only. Always refer to the Page 12 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure
TWO AXIS CUT GEARS

DIFFERENTIAL BEARING PRELOAD CHECK

With an inch pound torque wrench (2) measure Total
Torque To Rotate (TTTR). This is the final check on the
differential assembly before installing the axle shafts.
This will verify the correct differential bearing preload.

Total Torque To Rotate the differential is: Pinion Torque

To Rotate plus 0.79 - 1.24 N·m (7 - 11 in. lbs.).

NOTE: If TTTR is high, decrease the shim thickness

equally on both sides of the differential and check TTTR
again. If TTTR is low, increase the shims thickness
equally on both sides of the differential and check TTTR
again.

Note: This procedure is for training purposes only. Always refer to the Page 13 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

SPECIFICATIONS

AXLE

DESCRIPTION SPECIFICATION
Axle Ratio 3.21, 4.10
Ring Gear Diameter 226 mm (8.89 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Ring Gear Backlash 0.12 - 0.20 mm (0.005 - 0.008 in.)
Pinion Torque To Rotate - Original Bearings 1 - 2.2 N·m (10 - 20 in. lbs.)
Pinion Torque To Rotate - New Bearings 2.2 - 4.5 N·m (20 - 40 in. lbs.)
Total Torque To Rotate: Pinion Torque To Rotate plus 0.79 - 1.24 N·m (7 - 11 in. lbs.)

TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Ring Gear Bolts 183 135 -
Pinion Nut 217–271 160–200 -
Axle Retainer Nuts 61 45 -

Note: This procedure is for training purposes only. Always refer to the Page 14 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

GEAR, RING AND PINION

INSTALLATION
1. Install rear bearing cup with Installer C-4308
(1) and Handle C-4171 (2).

2. Install front bearing cup with Installer D-129

(1) and Handle C-4171 (2).

Note: This procedure is for training purposes only. Always refer to the Page 15 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

3. Install front pinion bearing (1).

4. Install front pinion bearing oil slinger (1).

Note: This procedure is for training purposes only. Always refer to the Page 16 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

5. Apply a light coating of gear lubricant on

the lip of pinion seal. Install pinion seal with
Installer 8681 (1) and Handle C-4171 (2).

6. Install pinion depth shims (1) on the pinion

shaft (2).

Note: This procedure is for training purposes only. Always refer to the Page 17 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

7. Install rear pinion bearing (4) on the pinion

gear (3) with Installer C-4040 (2) and a
press (1).

8. Install collapsible spacer (1) on pinion shaft

(3).

Note: This procedure is for training purposes only. Always refer to the Page 18 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

9. Install pinion gear into the housing.

10. Install pinion flange (1) with Installer C-3718
(2).

11. Install pinion washer and a new nut. Hold

pinion flange with Spanner Wrench 6958
and tighten pinion nut to 217 N·m (160 ft.
lbs.).
12. Set torque wrench to 271 N·m (200 ft. lbs.)
and tighten pinion nut in 6.8 N·m (5 ft. lbs.)
increments until Pinion Torque To Rotate
specification is achieved.

Note: This procedure is for training purposes only. Always refer to the Page 19 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

13. Measure Pinion Torque To Rotate (1)

(PTTR) after each 6.8 N·m (5 ft. lbs.)
increment with an inch pound torque wrench
(2).
Pinion Torque To Rotate is:

Original Bearings - 1 to 2 N·m (10 to 20 in.

lbs.)
New Bearings - 2 to 4.5 N·m (20 to 40 in.
lbs.)

14. Install new ring gear bolts (1) and alternately

tighten to 183 N·m (135 ft. lbs.).
CAUTION: Never reuse ring gear bolts,
the bolts can fracture causing extensive
damage. Failure to these instruction may
result in damage.
15. Install differential in axle housing and verify
gear backlash, mesh and contact pattern.

Note: This procedure is for training purposes only. Always refer to the Page 20 of 21
service information for the most recent and accurate procedures.
 Dana 44 (226RBI): Ring and Pinion Gear Setup and Adjustment Procedure

16. Measure Total Torque To Rotate (TTTR)

with an inch pound torque wrench (2) before
installing the axle shafts.

Total Torque To Rotate is: Pinion Torque To

Rotate plus 0.79 - 1.24 N·m (7 - 11 in lbs.).

NOTE: If TTTR is too high, decrease shim

thickness equally from both sides of
the differential and check TTTR again. If
TTTR is too low, increase shim thickness
equally to both sides of the differential
and check TTTR again.

Note: This procedure is for training purposes only. Always refer to the Page 21 of 21
service information for the most recent and accurate procedures.