Utility ATV repair and maintenance & Troubleshooting Place your Utility ATV Repair and Maintenance questions/thoughts here... *not performance*

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Old 07-26-2012, 08:42 PM   #1
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Anyone know how to shim a diff?

I blew my rear diff and I have everything to build the diff from scratch but I need know how to install the pinion and how to shim the diff
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Old 07-26-2012, 11:22 PM   #2
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Also my diff case isn't threaded do I tap and dye them or what do I do!!!
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Old 07-26-2012, 11:23 PM   #3
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From what I have read the diff bolts they send are self tapping so you just thread them in straight
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Old 07-27-2012, 12:11 AM   #4
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Darn lol I'll have to get some bolts. I am
Unsure of how you measure to find out what shims you use too...
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Old 07-27-2012, 01:47 PM   #5
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 Quote: Originally Posted by blissman20 View Post
Darn lol I'll have to get some bolts. I am
Unsure of how you measure to find out what shims you use too...

Probably no reason you could not tap the holes yourself and reuse the old bolts instead of purchasing the self tapping variety?

Back lash is set by varying the left and right side shim thickness and end play is set by the total thickness of both shims on each side of the ring gear.

Measuring for end play is a matter of pushing the ring gear left or right and noting how much movement it has with a dial indicator when the ring gear is installed and cover torqued to specs.

Back lash is the space between the teeth where the ring gear mates to the pinion gear. It would be nice if they specified backlash tolerance as degrees of free rotation of the pinion or slop in the gearing. Actual measuring of backlash clearance can be done with Plastigage to check it. It's quick and easy and nearly as accurate to just compare the degrees rotation of the pinion with a known good preset (new) differential once end play is set if you have access to one.

I'll set end play without the pinion installed so I know what the total shim thickness of both shims needs to be without the possibility of interference of the ring gear contacting the pinion. To set back lash then its a matter of subtracting .1 mm from one side and adding .1 mm to the other side to get backlash in spec.

From the manual (Agreed not very clear)

"Gear Case Side - install a 1.3-1.4 mm shim and
tighten the bolts to 28 ft-lb. Verify backlash to
be within a range of 0.28-0.38 mm (0.011-0.015
in.) and end-play to be within a range of
0.10-0.20 mm (0.004-0.008 in.). If not within
specification range, reselect shim until backlash
specification range can be verified."

Note that there is a slight (tiny) bevel on the inside inner lip of a shim. That bevel must face towards the inside or towards the ring gear
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Troubleshooting First Steps, An amazing number of problems are cured with just these two items.

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Old 07-27-2012, 02:25 PM   #6
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If you bought a new diff why are you shimming it?
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Old 07-27-2012, 02:43 PM   #7
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 Quote: Originally Posted by doorfx View Post
If you bought a new diff why are you shimming it?
Maybe he just bought a new diff case and is reusing old parts? Since he has untapped holes in the housing it's obvious he did not buy a complete assembled differential. That should of answered your own question <grin>
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Have a Problem?

Troubleshooting First Steps, An amazing number of problems are cured with just these two items.

1. Make sure your battery is FULLY Charged.
2. Try a new spark plug.

Search threads, Check Pinned Section. Pinned Topics Manual or wiring diagram? Manuals
http://countrycat.com/ccstore/index...._Diagrams.html

Improving Search.

Better results when searching for specific information. To find threads where ALL the words, instead of ANY of the words "650H1, Carb, Jetting, Needle Jet, Snorkel" were found...Open up a search window in www.google.com In the find box type without the quotes "650H1 Carb Jetting Needle Jet Snorkel site:Arcticchat.com" & Press return. Find threads, replies or topics by a specific member; just by inserting their user name into the search list; Chances are, your problem is NOT unique and it has been solved many times before.

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Old 07-27-2012, 03:21 PM   #8
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Smartass!! Lol even the mounting holes come untapped
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2013 700 XT trv eps stock



It's mind over matter,If you don't mind,
It just doesn't matter

No Boost No Bottle
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Old 07-27-2012, 08:03 PM   #9
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2010 Mileage: 400 bike broke
Thanks wyo.... Door I'll pm you the story. But I have all the parts separately to build the diff lol
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