Pinion Gear/Ring Gear - Installation

INSTALLATION






NOTE: A pinion depth shim is located under the rear pinion bearing. If ring and pinion gears are reused, the original pinion depth shim/oil baffle can be used. Refer to Adjustments (Pinion Gear Depth) to select the proper shim thickness if ring and pinion gear are replaced.

1. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (2).





2. Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171 (2).





3. Install pinion front bearing in housing.
4. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer C-4076-B (1) and Handle C-4735 (2).





5. Install pinion depth shim (1) on pinion shaft (2).





6. Install rear bearing (4) on pinion gear (3) and slinger if equipped, with Installer 6448A (2) and a press (1).





7. Install a new collapsible spacer (1) on pinion shaft (3) and install pinion in housing.





8. Install pinion flange (1) with Installer C-3718 (2).
9. Install a new nut on the pinion.
10. Holding flange (1) with Holder C-3281 and tighten nut with torque wrench to 285 Nm (210 ft. lbs.).

NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point.






11. Measure pinion torque to rotating (1) with an inch pound torque wrench (2). Measure pinion torque to rotating frequently to avoid over over-crushing the collapsible spacer.
Pinion Torque To Rotate is:

- Original Bearings 1 - 2.2 Nm (10 - 20 in. lbs.)
- New Bearings 1- 5 Nm (10 - 30 in. lbs.)
If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved.

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded a new collapsible spacer must be installed. Failure to follow these instructions will damage the axle.


RING GEAR INSTALLATION - GAS ENGINES





1. Install ring gear on differential case.
2. Invert differential case in the vise.
3. Install new ring gear (2) bolts (1) and alternately tighten to 122 Nm (90 ft. lbs.).

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

4. Install differential in axle housing and verify gear mesh refer to Adjustments (Gear Contact Pattern).

RING GEAR INSTALLATION - DIESEL ENGINES





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

CAUTION: A bearing heater is used to install the ring gear on the differential. Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 107 - 121 Celsius (225° Min. - 250° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and 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.

1. Heat ring gear (1) on bearing heater (2) to 107 - 121 Celsius (225° Min. - 250° Max Fahrenheit).





2. Turn ring gear over on bearing heater with welding gloves once the temperature has been reached.
3. Install left hand threaded Pins 10126-2 (1) into ring gear (2).





4. Install ring gear (1) on differential (2) using Pins 10126-2 (3) to align ring gear bolts hole.





5. Allow ring gear time to cool, then turn the differential over and remove Pins 10126-2 (1) from ring gear (2).





6. Install new left hand threaded ring gear (2) bolts (1) and alternately tighten to 27 Nm (20 ft. lbs.). Then with torque angle gauge alternately tighten to 95 degrees ± 5 degrees.

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

7. Install differential in axle housing and verify gear mesh refer to Adjustments (Gear Contact Pattern).