GEAR-PINION/RING
REMOVAL
NOTE: Ring and pinion gear are serviced as a matched set. Never replace one gear without replacing the other matching gear.
1. Remove differential from axle housing.
2. Remove ring gear bolts (1) and drive ring gear (2) from differential case.
3. Hold pinion flange (2) with Wrench C-3281 (1) and remove pinion nut.
4. Remove pinion flange (1) with Remover 8992 (2).
5. Remove pinion gear (2) from housing with Driver 8976 (1).
6. Remove pinion seal with a seal puller.
7. Remove oil slinger (1).
8. Remove front pinion bearing (1) from housing.
9. Remove rear pinion bearing cup with Remover D-162 and Handle C-4171. Cup can also be removed with a hammer and punch.
10. Remove front pinion bearing cup with a hammer and punch. Place punch in the notches (2) on either side of the cup.
11. Remove collapsible spacer (1) from pinion shaft (2).
12. Remove rear pinion bearing from pinion shaft (1) with Puller/Press C-293-PA (2) and Adapters C-293-37 (3).
13. Remove pinion depth shim (1) from pinion shaft (2).
INSTALLATION
1. Install rear pinion bearing cup with Installer D-111 (1) and Handle C-4171.
2. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).
3. Install front pinion bearing (1 ) into differential housing.
4. Install oil slinger (1) into differential housing.
5. Apply a light coating of gear lubricant on the lip of the pinion seal. Install new pinion seal in differential housing with Installer 8889 (1) and hammer (2).
6. Install pinion depth shim (1) on pinion gear shaft (2).
WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.
CAUTION: A bearing heater (2) is used to heat front pinion bearing (1). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat bearing to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
7. Heat rear pinion bearing (1) to a maximum of 177 Celsius (350° Fahrenheit) with bearing heater (2). With tongs or welding gloves install bearing on pinion gear shaft. Rear pinion bearing can also be installer with Installer MD998805.
8. Install new collapsible spacer (1) on pinion gear shaft (2).
9. Install pinion gear in differential housing.
10. Install companion flange (1) on pinion shaft with Installer C-3718 (2).
11. Hold companion flange (2) with Wrench C-3281 (1) and tighten pinion nut to 298 N·m (220 ft. lbs.).
12. Set torque wrench to 678 N·m (500 ft. lbs.) and tighten pinion nut in 6.8 N·m (5 ft. lbs.) increment until Pinion Torque To Rotate specification is achieved.
13. Measure Pinion Torque To Rotate after each 6.8 N·m (5 ft. lbs.) increment with an inch pound torque wrench (2). Pinion Torque To Rotate Specification:
- Original Bearings - 1 to 2 N·m (10 to 20 in. lbs.)
- New Bearings - 2 to 3.15 N·m (18 to 28 in. lbs.)
14. Install ring gear (2) on differential case and install new bolts (1) and tighten to 170 N·m (125 ft. lbs.).
15. Install the differential into the housing.
16. Verify gear backlash, mesh and gear tooth contact pattern.
17. Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is Pinion Torque To Rotate plus 0.44 to 1.34 N·m (4 to 12 in. lbs.).
If TTTR is too high, decrease shim thickness equally from both sides of the differential and check TTTR again. If TTTR is too low, increase shim thickness equally to both sides of the differential and check TTTR again.