Installation

INSTALLATION





NOTE: The ring gear and pinion are serviced in a matched set. Never replace 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 8692 (2) and Handle C-4171 (3).




2. Install front pinion bearing cup with Installer 8693 and Handle C-4171.
3. Lubricate front pinion bearing and install bearing in the housing.
4. Apply a light coating of gear lubricant on the lip of pinion seal.
5. Install pinion seal with Installer 8695 (2) and Handle C-4171 (1).




6. Place pinion depth shim (1) on the pinion shaft (2).




7. Install rear pinion bearing (4) with Installer 6448A (2) and a press (1).




8. Install new collapsible spacer (1) onto the pinion shaft.
9. Lubricate rear pinion bearing and install the pinion gear in the housing.




10. Install companion flange with Installer C-3718 and Holder 6719 (2).
11. Install new pinion nut and tighten to 271 Nm (200 ft. lbs.).
12. Using Holder 6719 and a torque wrench set at 475 Nm (350 ft. lbs.). Tighten pinion nut until bearing end play is eliminated.




13. Rotate pinion several times to seat pinion bearings.
14. Tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Measure torque to rotate frequently to avoid over crushing the collapsible spacer.

Pinion Torque To Rotate is:

- Original Bearings: 1 - 2.5 Nm (10 - 20 in. lbs.)
- New Bearings: 2.0 - 2.8 Nm (18 - 25 in. lbs.)

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.




15. Invert start two ring gear bolts (1) to provide ring gear (2) bolt hole alignment.
16. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction will result in damage.

17. Install differential in housing and verify gear mesh, backlash and contact pattern.