Pinion Gear/Ring Gear - Installation

INSTALLATION

Special Tools:














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





2. Install rear pinion bearing cup with Installer (1) and Handle (2), if bearing is replaced.





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





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





5. Install new collapsible spacer (1) on pinion gear (2).
6. Lubricate pinion and bearings (3).





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





8. Install new pinion seal with Installer (2) and Handle (1).
9. Apply a light coat of teflon sealant to the pinion flange splines.
10. Hold pinion and lightly tap the pinion flange onto the pinion shaft, until a few threads are showing.
11. Install pinion flange washer and new pinion nut.
12. Hold pinion flange with Flange Wrench and tighten pinion nut until end play is eliminated.





13. Rotate pinion several times to seat pinion bearings.
14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is reached.Pinion Torque To Rotate is:

- New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.)
- Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 in. lbs.)

15. Rotate pinion several times then verify pinion torque to rotate again.
16. Position ring gear on differential case and start two new ring gear bolts.
17. Install remaining new ring gear bolts and tighten them alternately to seat the ring gear. Torque ring gear bolts to 140 Nm (103 ft. lbs.).
18. Install differential in housing.
19. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench.Total Torque to Rotate is:

- New Bearings: 3.4 - 5.6 Nm (30 - 50 in. lbs.)
- Original Bearings: 2.8 - 5.1 Nm (25 - 45 in. lbs.)
NOTE: If TTTR is to high, back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low, tighten adjusters evenly on both sides slightly and check TTTR again.

20. Verify ring gear backlash and gear contact pattern.