I have run into a problem setting the depth on this 14bolt's pinion. The depth setting marked on the end of the pinion is 2.426". I know my caliper is a little cheesey, but bear with me here. When I measure from the flats off the carrier bearing caps I am only 2.235". So I need to pick up another .201". Here is a pic.

http://bbs.off-road.com/wwwthreads_uploads/9-709965-DSC00009a.JPG

This is with the original shim in place which is .125" My master install kit only includes another .10" worth of shims. I am believing that a total of .326" worth of shims would be excessive.

Any ideas why this might be so far out of whack? Or would you consider this within specs?

The actual pinion preload was set at a local gear shop as my impact wrench would not crush the sleeve. But that should not even matter.

That doesn't really tell you much. That spec is just designed to get you close. Drop the carrier in, set backlash, and check the pattern. Then add/remove shims as necessary. If you still feel something isn't right, make sure the bearings and races are seated.

You're not making an accurate measurement anyway.

I know I am not very accurate, but I am concerned that I am so far out that I have a problem. Lets say my measurement is off by 1/8"+/- :eek: I still would need .25" of shims. Something seems wrong.

It'llb e much easier to just run the pattern and see wheer it is, then adjust accordingly as opposed to trying to make the innacurate measurements that you are. If the pattern is towards the outside edge, you'll need more shims, if it's on the inside edge, that's good, that is the strongest place in the gear.

Ditto what wilson said.... gears are lots of guess and check... load up that carrier, and check the pattern

Originally posted by BigHG
I know I am not very accurate, but I am concerned that I am so far out that I have a problem. Lets say my measurement is off by 1/8"+/- :eek: I still would need .25" of shims. Something seems wrong.

When measuring the pinion depth on a Dana axle, I believe a spacer of some specific thickness is supposed to be used. Odd's are the 14 is the same....You're only measuring from what you believe is the center of the housing. Unless you have the documentation on the specifics of making that measurement and the proper tools, then you're wasting your time. Final adjustments are always made by the pattern regardless of what the gear specs are. Get the pattern, I bet you're not as far off as you think you are.