GEAR-PINION/RING
REMOVAL
NOTE: The ring and pinion gears are serviced in a matched set. Never replace one gear without replacing the other gear.
1. Remove differential from housing.
2. Remove ring gear (2) bolts (1) and remove ring gear from differential case.
3. Hold pinion flange (1) with Spanner Wrench 6958 (2) and remove pinion nut and washer.
4. Remove pinion flange (1) with Puller C-452.
5. Remove pinion gear (1) from housing with Driver 8976 (1).
6. Remove pinion shaft seal with seal puller.
7. Remove oil slinger (1).
8. Remove front pinion bearing (1).
9. Remove front pinion bearing cup with Remover D-103 (1) and Handle C-4171 (2).
10. Remove rear bearing cup from housing with Remover C4307 (1) and Handle C-4171 (2).
11. Remove collapsible spacer (1) from pinion gear shaft (2).
12. Remove rear bearing from the pinion shaft (1) with Puller C-293-PA (2) and Adapters C-293-42 (3).
13. Remove depth shims (1) from the pinion shaft (2) and record the shims thickness.
INSTALLATION
1. Install pinion rear bearing cup with Installer C-4308 (1) and Driver Handle C-4171 (2).
2. Install pinion front bearing cup with Installer D-129 (1) and Handle C-4171 (2).
3. Install pinion front bearing (1).
4. Install pinion front bearing oil slinger (1).
5. Lightly coating gear lubricant on the pinion seal lip and install seal with Installer 8681 (1) and Handle C-4171 (1) .
6. Install pinion depth shims (1) on pinion gear (2).
7. Install rear 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 gear in the housing.
9. Install pinion flange with Spanner Wrench 6958 and Installer C-3718 (2).
10. Install flange washer and a new nut on the pinion gear. Tighten pinion nut to 271 N·m (200 ft. lbs.).
11. With Spanner Wrench 6958 and a torque wrench, slowly tighten pinion nut in 6.8 N·m (5 ft. lbs.) increments until pinion torque to rotating achieved. Measure pinion torque to rotating frequently to avoid over crushing the collapsible spacer.
12. Measure pinion (2) torque to rotating with an inch pound torque wrench (1).
The Pinion Torque To Rotate is:
- Original Bearings: 1 - 2 N·m (10 - 20 in. lbs.).
- New Bearings: 2 - 4 N·m (20 - 35 in. lbs.).
CAUTION: If maximum tightening torque of 475 N·m (350 ft. lbs.) is reached before torque to rotate is achieved, the collapsible spacer may have been damaged.
Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction may result in damage.
13. Install ring gear with new ring gear (2) bolts (1) and alternately tighten to 136 N·m (100 ft. lbs.).
CAUTION: Do not reuse ring gear bolts, the bolts can fracture causing extensive damage. Failure to follow these instruction may result in damage.
14. Install differential case in the axle housing.
15. Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (1) 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.