Overhaul (Gear - Pinion/Ring)
GEAR-PINION/RING/TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear.
1. Remove differential from differential housing.
2. Place differential case in a vise with soft metal jaw protectors.
3. Remove ring gear bolts and drive ring gear (2) off the differential case (1) with a soft hammer (3).
4. Install bolts into two of the threaded holes in the pinion flange 180 degrees apart.
5. Position Holder 6719A against flange and install a bolt and washer into one of the remaining threaded holes. Tighten bolts so the Holder 6719A is held to the flange.
6. Use Holder 6719A to hold flange and remove the companion flange nut and washer.
7. Remove flange (1) from pinion with Puller C-452 (2).
8. Remove pinion from housing with a soft hammer (1).
9. Remove pinion seal with a pry tool or slide-hammer mounted screw.
10. Remove oil slinger if equipped and front pinion bearing.
11. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171 (2).
12. Remove rear bearing cup from housing with Remover C-4307 (1) and Handle C-4171 (2).
13. Remove collapsible spacer (1) from pinion gear.
14. Remove rear bearing from the pinion with Puller/ Press C-293-PA (1) and Adapters C-293-47 (3).
15. Remove depth shims from the pinion shaft and record shim thickness.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting.
1. Install rear pinion bearing cup with Installer C-4310 (1) and Driver Handle C-4171 (2).
2. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).
3. Lubricate and install front pinion bearing.
4. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B (3) and Handle C-4735 (1).
5. Install proper thickness depth shim (1) on the pinion gear (2).
6. Install rear bearing (4) on pinion gear (3) with Installer C-3095-A (2) and a press (1).
7. Install a new collapsible spacer (1) on pinion shaft. Lubricate rear bearing and install pinion into the housing.
8. Install pinion flange with Installer C-3718.
9. Install bolts into two of the threaded holes in the flange 180 degrees apart.
10. Position Holder 6719A against the flange and install a bolt and washer into one of the remaining threaded holes. Tighten bolts so the Holder 6719A is held to the flange.
11. Install flange washer and new nut on the pinion and tighten nut until there is zero bearing end-play
12. With a torque wrench (3) tighten the pinion nut to 285 Nm (210 ft. lbs.).
CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. Failure to follow these instructions will result in damage.
13. Slowly tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently with an inch pound torque wrench (2) to avoid over crushing the collapsible spacer.
14. Check pinion rotating torque with an inch pound torque wrench. The pinion rotating torque should be:
Original Bearings: 1 to 2 Nm (10 to 20 inch lbs.).
New Bearings: 1.7 to 4 Nm (15 to 35 inch lbs.).
15. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position.
16. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
17. Invert the differential case in the vise.
18. Install new ring gear bolts (2) and alternately tighten to 157 Nm (115 ft. lbs.).
CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in bolts fracture.
19. Install differential in housing and verify gear mesh and contact pattern.