Powertrax 4110 - Manual (Page 19)

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The last portion of the turn should be difficult because pre-load is
being applied to the bearings by spreading the caps apart as the
adjuster is being turned in.
9. Insert an axle shaft or bar into one of the axle shaft
holes in the differential case to help with holding the assembly or
place it in a large vise, and torque the cap bolts to their correct
value (see shop manual).
10. Install the adjuster locks and torque the bolts. Be
sure that they are located in the marked holes (as shown in Fig-
ure 14).
11. As an additional check to be sure that everything
has been installed correctly, use a small ruler, vernier caliper or
blade-type feeler gauge. The distance between the halves of the
LOCK-RIGHT, that is, between the two drivers, should be about
5/32-inch (.152-inch, or 3,86-mm). The tolerance limits are be-
tween .145-inch (3,68-mm) and .170-inch (4,32-mm). If this dis-
tance is much over .170-inch, either the case is quite worn or
the thrust washers are missing or are too thin and the problem
should be corrected before proceeding further.
Assembly Inspection
1. Inspect your work. Look for anything that is not cor-
rect. Be sure that the drivers rotate back and forth smoothly,
stopping at the pinion shaft. Use a light to see that the spacers
(and thrust block, if used) are in place and that the springs are
working properly.
When the above installation steps are completed, all the
parts should be in exactly the same positions as they were when
the installation began. The backlash and pre-load settings should
be unchanged from before and no further adjustments will be
needed. To be certain, rock the ring gear back and forth to see if
the backlash appears to be the same as it was prior to the instal-
lation. If not, it will need to be reset with a dial indicator as de-
scribed in the shop manual. Rotate the ring gear one revolution
to be sure that nothing is binding.