Mad Lab Ring and Pinion set-up:

Dana 44 and 60

1. Remove old ring and pinion.
    
2. Knock out pinion races (shims are located behind the races, keep for later reference, these set the depth. Also keep shims behind the front bearing, these set the pre load).
    
3. Clean, clean, clean.
    
4.  Set the pinion depth: The pinion depth is the distance from the Center line of the Ring Gear Carrier to the pinion. Since most people don't have the depth gauge many times you can cheat as long as the pinion setting is marked on the pinion your putting in and the one you take out. This way you can take the difference in the setting and then add or subtract the shims.
   
   Example: (and remember how an indicator reads if your coming off centerline of the ring gear)
   The pinion in the housing has a + 3 (or whatever number) and the pinion you are putting in has a + 3 you are pretty safe in using the same shims that
   are already in the housing. Just keep them and put them back in with the new race and bearing. ( always use a new race and bearing when setting up gears....it costs a little more but well worth it.)
   
   Now if the existing pinion has a - 3 and the pinion you are installing is a +2 then you have to take the existing shims and add .005 thousandths (remember you have to count 0)
   
   If the pinion coming out is +2 and the one going in is -3 then it's just the opposite. You take the existing shims and subtract .005.
   
   Pinion Picture
    
5. Now take the numbers you have and add or subtract them, take the existing shims and add or subtract to them (depending on you + or - pinion numbers) Take the now existing shims and put them in the housing where the bigger pinion race goes then drive the race in on top of them. Next slide the pinion in (the bearing should already be pressed on the pinion, there are no shims between the pinion and pinion bearing) Now take the pre load shims and slide them on the small bearing end then slide the small bearing on. (DO NOT PUT SEAL ON YET!) Put the yoke on and tighten it down. If Pinion is loose take the yoke and front bearing back off and take some shims OUT. If the pinion turns tight and hard to move ADD shims. You the yoke tight but you want it to turn with just a little resistant (around 5-10 INCH pounds). Keep adding or subtracting shims until your satisfied it's not too loose or too tight. Once you get this take the yoke off one more time and drive the seal (slightly grease the rubber on the seal) in then put it back together for good.
    
6. Now it's time to put the ring gear in. Take the carrier and take the old ring gear off. Clean, clean, and clean the carrier. Put a little Locktite on the bolts and put the ring gear on. If your using an air wrench DO NOT zip down the bolts. They are hardened and may break. Run them down slow and once they are good a snug then go ahead and put the air to the wrench.
    
7. I use honed out bearings to set my backlash. This makes it much easier to change the shims in and out because they are behind the carrier bearings. You should have a shim kit because you'll probably need it. Press or torch the old bearings off the carrier and then take two or three shims and put them on each side along with your honed bearings and put them in the carrier. You should have quite a bit of resistance sliding the chunk in when it's tight in the housing you know you have the right amount of shims....but they may not be in the right place. Take the indicator (regular dial indicator) and check to see what the backlash (space between the gear teeth touching) reading is by holding the pinion yoke with one hand and barely moving the ring gear back and forth until you feel the teeth touching. The indicator reading needs to be .004 thousandths - .012 thousandths with .006 being the ideal set-up, which both set-up on this page are at: .006.
   A. If the gear is a low or no reading take a shim off the ring side and put it on the opposite side.
   B. If the gear is a high reading. (ex: .020) take from the opposite side and add to the ring side.
   Do this until you have the proper reading. A crow-bar is helpful getting the chunk in and out of the housing. DO NOT pry on the gears pry on the bolt head holding the ring gear on.
   
   Picture 1 of Gear
   Picture 2 of Gear
   
   Once you get the proper reading. Check the pattern. You can use Persian Blue or just use grease. Take the grease and spread it on three or four ring gear teeth. Take the pinion and turn it until the ring gear does a complete rotation. Then turn the pinion the opposite direction a complete rotation. Look at the pattern the grease leave on the teeth on both sides of the tooth. Make sure the pinion tooth is traveling completely through and the grease pattern is centered on the ring gear teeth.
   
   Picture of Grease
   
   If it is then you need to take the chunk back out and remove the honed bearings and press the new bearings on then reinstall the chunk. Check the backlash and pattern one more time to make sure nothing change (which it shouldn't) torque your housing cap bolts down, replace the cover and add the gear oil and your ready to wheel.

This page last updated on 03/04/2005.