GEAR-PINION/RING
REMOVAL
NOTE: The ring and pinion gears are serviced as a matched set. Never replace one gear without replacing the other matched gear.
1. Remove differential from axle housing.
2. Remove ring gear bolts (1) and remove ring gear (2) from differential case.
3. Hold pinion flange (1) with Flange Wrench C-3281 (2) and remove the pinion nut.
4. Remove pinion flange (1) with Puller C-452 (2).
5. Drive pinion out of the housing with a dead blow hammer (1).
6. Remove pinion seal with seal puller.
7. Remove oil slinger (1).
8. Remove front bearing (1).
9. Remove front pinion bearing cup with Remover D-149 (1) and Handle C-4171 (2).
10. Remove rear pinion bearing cup and oil baffle with a hammer and brass drift.
11. Remove collapsible spacer (1) from pinion shaft (2).
12. Remove rear pinion bearing from pinion shaft (1) with Puller C-293-PA (2) and Adapters C-293-48 (3).
13. Remove pinion depth shim (1) from the pinion shaft (2) and record thickness.
INSTALLATION
1. Install oil baffle in rear bearing cup bore then install rear bearing cup with Installer C-4308 (1) and Handle C-4171 (2).
2. Install front bearing cup with Installer D-146 (1) and Handle C-4171 (2).
3. Install front pinion bearing (1) into the housing.
4. Install front pinion bearing oil slinger (1) into the housing.
5. Apply a light coating of gear lubricant on pinion seal lip and install seal with Installer 8681 (1) and Handle C-4171 (2).
6. Install pinion depth shim (1) on pinion shaft (2).
7. Install rear pinion bearing (4) on pinion gear (3) with Installer C-4040 (2) and a press (1).
8. Install new collapsible spacer (1) on pinion shaft (2) and install pinion into the housing.
9. Install pinion flange (1) with Installer 8112 (2) and Cup 8109.
10. Install new pinion nut.
11. With Flange Wrench C-3281 (2) and torque wrench tighten pinion nut to 217 N·m (160 ft. lbs.).
12. Using Flange Wrench C-3281 and torque wrench set at 542 N·m (400 ft. lbs.). Slowly tighten the nut in 6.8 N·m (5 ft. lb.) increments until the pinion torque to rotate is achieved. Measure pinion (1) torque to rotate with an inch pound torque wrench (2) frequently to avoid over crushing the collapsible spacer.
Pinion Torque To Rotate (PTTR) is:
- Original Bearings: 1.13 - 2.26 N·m (10 - 20 in. lbs.).
- New Bearings: 1.7 - 3.4 N·m (15 - 30 in. lbs.).
CAUTION: If more than 542 N·m (400 ft. lbs.) torque is required to crush the collapsible spacer, the spacer is defective and must be replaced. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions may result in damage.
13. Install ring gear with new ring gear bolts (1) and alternately tighten to 108 N·m (80 ft. lbs.).
CAUTION: Never reuse ring gear bolts. Failure to follow these instructions may result in damage.
14. Install differential case in to axle housing.
15. Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shafts. This will verify differential bearing preload.
Total Torque To Rotate is: Pinion Torque To Rotate (PTTR) plus 0.79 - 1.24 N·m (7 - 11 in lbs.).
NOTE: 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.