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The Terminator
Driveline
03 IRS: Speed sensitive 'clunking'
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<blockquote data-quote="03SVTCOBRA10TH" data-source="post: 7986804" data-attributes="member: 11983"><p>After another look at your pics they look like FORD gears. I would try the 0.020 shim first.</p><p></p><p>Can you get a thickness on the carrier shims?? You will most likely need to put the thicker one on the right side to correct you backlash. </p><p></p><p>When you tear down the diff, make sure to get all the gear oil off, use brake cleaner if you don't have a parts washer. You might have to put the diff in a vice and use a propane torch for a few secs where the ring gear mates to the diff at the spot where each bolt is, if the installer used a lot of red locktite. </p><p></p><p>Once you have the ring gear off, remove the retaining bolt that holds the shaft in place. Then remove the shaft. Then you will need to remove the S-spring, take a pic of its orientation, then use a long socket and a hammer and tap it out slowly, I cover it witha rag so it dosen't fly away. </p><p></p><p>Then rotate the larger drive gears, that will rotate the spidergears and thier bearing races. Then remove the drive gears. Pull off the old cluthces and steel plates. Then replace the cluthces and steels in the order they come in the kit. </p><p></p><p>If you want to use the alternate method you wil need to save the 2 best clutches from the diff and remove one steel plate from the new kit. The alternate stacking order is 0.030 shim, C,S,C,S,C,S,C side gear, diff, side gear, C,S,C,S,C,S,C, 0.030 shim. </p><p></p><p>Then put the drive gears back in and then line up the spider gears and thier bearing races and you should be able to rotate the drive gears so the spider gears go back into place. And if you did it correctly, they will line up with the holes for the shaft. </p><p></p><p>Then you need to pull out the pic and orient the S-spring, put the edge of it in the space it goes, then use the 2x4 to hammer it in (this is the complicated part untill you have done it a few times, you may need to call me so I can walk you through it a little better). Then put the shaft in and the retaining bolt. The the ring gear and bolts and then you are ready to check/ set backlash.</p></blockquote><p></p>
[QUOTE="03SVTCOBRA10TH, post: 7986804, member: 11983"] After another look at your pics they look like FORD gears. I would try the 0.020 shim first. Can you get a thickness on the carrier shims?? You will most likely need to put the thicker one on the right side to correct you backlash. When you tear down the diff, make sure to get all the gear oil off, use brake cleaner if you don't have a parts washer. You might have to put the diff in a vice and use a propane torch for a few secs where the ring gear mates to the diff at the spot where each bolt is, if the installer used a lot of red locktite. Once you have the ring gear off, remove the retaining bolt that holds the shaft in place. Then remove the shaft. Then you will need to remove the S-spring, take a pic of its orientation, then use a long socket and a hammer and tap it out slowly, I cover it witha rag so it dosen't fly away. Then rotate the larger drive gears, that will rotate the spidergears and thier bearing races. Then remove the drive gears. Pull off the old cluthces and steel plates. Then replace the cluthces and steels in the order they come in the kit. If you want to use the alternate method you wil need to save the 2 best clutches from the diff and remove one steel plate from the new kit. The alternate stacking order is 0.030 shim, C,S,C,S,C,S,C side gear, diff, side gear, C,S,C,S,C,S,C, 0.030 shim. Then put the drive gears back in and then line up the spider gears and thier bearing races and you should be able to rotate the drive gears so the spider gears go back into place. And if you did it correctly, they will line up with the holes for the shaft. Then you need to pull out the pic and orient the S-spring, put the edge of it in the space it goes, then use the 2x4 to hammer it in (this is the complicated part untill you have done it a few times, you may need to call me so I can walk you through it a little better). Then put the shaft in and the retaining bolt. The the ring gear and bolts and then you are ready to check/ set backlash. [/QUOTE]
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03 IRS: Speed sensitive 'clunking'
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