Pinion Gear/Ring Gear - Installation

INSTALLATION

Special Tools:










1. Install front pinion bearing cup with Installer (1) and handle (2).





2. Install pinion depth shim (1) in rear pinion bearing cup bore.





3. Install rear pinion bearing cup with Installer (1) and handle (2).






WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Pinion bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.






4. Heat rear pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on pinion (2) with tongs or welding gloves.





5. Rear pinion bearing (1) can also be installed with Installer (2) and a press.





6. Install pinion spacer (1) on pinion gear (2).





7. Install pinion bearing preload shim (1) on pinion gear (2).





8. Install pinion gear (1) into differential housing.





9. Heat front pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on pinion (2) with tongs or welding gloves.





10. Install pinion seal with Installer (1).





11. Install pinion flange on pinion shaft.
12. Hold pinion flange (1) with Holder (2) and tighten pinion flange nut to 500 Nm (369 ft. lbs.).





13. Bend pinion flange (1) nut (2) collar into pinion keyway with a hammer and punch.





14. Align ring gear (1) to differential case with two new ring gear bolts (2).





15. Install remaining new ring gear bolts and tighten to 175 Nm (139 ft. lbs.).





16. Install differential into housing.
17. Check Total Torque To Rotate. TTTR is: Pinion Torque To Rotate plus 1.5 Nm ± 0.5 Nm (13 in. lbs. ± 4.4 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.

18. Verify ring gear backlash and gear contact pattern.