GEAR-PINION/RING
REMOVAL
NOTE: The ring gear and pinion are serviced as a matched set. Never replace one gear without replacing the other matched gear.
1. Remove differential assembly from axle housing.
2. Remove ring gear bolt (1) and ring gear (2) from differential case.
3. Hold pinion flange (1) with Spanner Wrench 6958 (2) and remove the pinion nut and washer.
4. Remove pinion flange (1) with Puller C-452 (2).
5. Remove pinion gear (1) from the housing with Driver 8976 (2).
6. Remove collapsible spacer (1) from pinion (3).
7. Remove rear pinion bearing from pinion shaft (1) with Puller C-293-PA (2) and Adapters C-293-47 (3).
8. Remove and record pinion depth shims (1) from the pinion gear shaft (2).
9. Remove pinion seal with seal puller and remove oil slinger (1).
10. Remove front pinion bearing (1).
11. Remove front pinion bearing cup from differential housing with Remover D-103 (1) and Handle C-4171 (2).
12. Remove rear pinion bearing cup from differential housing with Remover C-4307 (1) and Handle C-4171 (2).
INSTALLATION
1. Install rear bearing cup with Installer C-4308 (1) and Handle C-4171 (2).
2. Install front bearing cup with Installer D-129 (1) and Handle C-4171 (2).
3. Install front pinion bearing (1).
4. Install front pinion bearing oil slinger (1).
5. Apply a light coating of gear lubricant on the lip of pinion seal. Install pinion seal with Installer 8681 (1) and Handle C-4171 (2).
6. Install pinion depth shims (1) on the pinion shaft (2).
7. Install rear pinion bearing (4) on the pinion gear (3) with Installer C-4040 (2) and a press (1).
8. Install collapsible spacer (1) on pinion shaft (3).
9. Install pinion gear into the housing.
10. Install pinion flange (1) with Installer C-3718 (2).
11. Install pinion washer and a new nut. Hold pinion flange with Spanner Wrench 6958 and tighten pinion nut to 217 N·m (160 ft. lbs.).
12. Set torque wrench to 271 N·m (200 ft. lbs.) and tighten pinion nut in 6.8 N·m (5 ft. lbs.) increments until Pinion Torque To Rotate specification is achieved.
13. Measure Pinion Torque To Rotate (1) (PTTR) after each 6.8 N·m (5 ft. lbs.) increment with an inch pound torque wrench (2).
Pinion Torque To Rotate is:
- Original Bearings - 1 to 2 N·m (10 to 20 in. lbs.)
- New Bearings - 2 to 4.5 N·m (20 to 40 in. lbs.)
14. Install new ring gear bolts (1) and alternately tighten to 136 N·m (100 ft. lbs.).
CAUTION: Never reuse ring gear bolts, the bolts can fracture causing extensive damage. Failure to these instruction may result in damage.
15. Install differential in axle housing and verify gear backlash, mesh and contact pattern.
16. Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shafts.
Total Torque To Rotate is: Pinion Torque To Rotate 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.