Ring and Pinion

GEAR-PINION/RING

REMOVAL

NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.

1. Mark pinion flange and propeller shaft for installation alignment.
2. Remove propeller shaft.
3. Remove differential from the housing.





4. Place differential case (1) on Plug 8964. Drive exciter ring (4) off the differential case with a hammer and punch (3).

NOTE: Do not remove the exciter ring if it is not being replaced.

5. Place differential case in a vise with soft metal jaw protectors.
6. Remove bolts holding ring gear to differential case.





7. Drive ring gear (2) from differential case (1) with a soft hammer (3).





8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut.





9. Remove pinion flange (1) from pinion with pinion Flange Puller 8992 (2).





10. Remove pinion gear (1) from housing with pinion Driver 8977 (2)and a hammer.

NOTE: Thread the driver on the pinion shaft till it bottoms out.

11. Remove pinion seal with a slide hammer or pry bar.
12. Remove front pinion bearing and discard bearing.

NOTE: Do not reuse front pinion bearing/cup.

13. Remove collapsible spacer from the pinion shaft.





14. Remove rear pinion bearing (1) with Bearing Splitter 1130 (2) and a press.
15. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims.
16. Remove front pinion bearing cup from the housing with a punch and hammer, and discard cup.

NOTE: Do not reuse front pinion bearing/cup.

17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced.

INSTALLATION





1. Install new front pinion bearing cup with Installer 8960 (1) and Handle C-4171 (2).





2. Install new rear pinion bearing cup with Installer 8968 (1) and Handle C-4171(2).





3. Install pinion depth shim (1) on the pinion gear shaft (2).





4. Install rear pinion bearing (4) with Installer D-389 (1) and a press (1).





5. Install new collapsible spacer (1) on the pinion (2).
6. Lubricate pinion and bearings.





7. Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (1).





8. Install new pinion seal with Installer 8896 (2) and Handle C-4171 (1).
9. Rotate pinion several times to seat bearings.
10. Apply a light coat of teflon sealant to the pinion flange splines.





11. Hold pinion and lightly tap the pinion flange (2) onto the pinion, until a few threads are showing.
12. Install pinion flange washer and new pinion nut.
13. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up.





14. Measure pinion rotating torque (1) with an inch pound torque wrench (2). Tighten pinion nut in small increments until pinion rotating torque is:
^ New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 inch lbs.)
^ Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 inch lbs.)

15. Rotate pinion several times then verify pinion rotating torque again.





16. Position the ring gear (2) on differential case (4) and start two new ring gear bolts.
17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear.
18. Torque ring gear bolts to 237 Nm (175 ft. lbs.).





19. If exciter ring was removed, position differential assembly on differential Plug 8965 and place exciter ring (1) on the differential case.
20. Install the exciter ring on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (2)
21. Install differential in housing and verify gear backlash and gear contact pattern.
22. Measure final rotating torque with an inch pound torque wrench. The final pinion rotating torque plus differential case bearing preload is:
^ New Bearings: 3.4 - 5.6 Nm (30 - 50 inch lbs.)
^ Original Bearings: 2.8 - 5.1 Nm (25 - 45 inch lbs.)

23. Install axle shafts.
24. Install the propeller shaft with the reference marks aligned.
25. Install differential cover with gasket and tighten bolts to 40 Nm (30 ft. lbs.).
26. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.).