Differential Ring And Pinion

Differential Ring And Pinion

Special Tools (1 Of 4):

Special Tools (2 Of 5):

Special Tools (3 Of 5):

Special Tools (4 Of 5):

Material:

Removal

1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

2. Remove and discard the 12 ring gear bolts.





3. NOTICE: Care should be taken not to damage the ring gear bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.





4. Position the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Collets, Differential Carrier Bearing Retaining Ring, Tube Remover and Bearing Tube Removal Screw.





5. Using 2 wrenches, remove the differential bearing.
- Repeat the procedure for the other differential bearing.





6. Using the Differential Carrier Bearing Installer, install the new differential bearings on the differential case.





7. To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.





8. Remove and discard the 4 bolts.





9. NOTE: The driveshaft flange fits tightly on the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the flange.

NOTE: It may be necessary to tap the driveshaft yoke with a plastic or rubber soft-faced hammer if a pry area is not present on the driveshaft yoke.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.





10. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove the pinion nut and washer.
- Discard the pinion nut.





11. Using the 2 Jaw Puller, remove the pinion flange.





12. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.
- Remove the oil slinger and the outer pinion bearing.





13. Install the Drive Pinion Thread Protector and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.





14. Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the cups.





Installation

1. Install the inner and outer bearing cups.

1. After placing the inner and outer bearing cups in their bores, place the Input Shaft Bearing Cup Installer on the inner pinion bearing cup.

2. Place the Drive Pinion Bearing Installer on the outer pinion bearing cup.

3. Install the Rear Axle Drawbar into the replacer tools.





2. Tighten the Rear Axle Drawbar to install the pinion bearing cups into their bores.





3. Make sure the cups are correctly seated in their bores.
- If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.





4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Assemble and position the Adapter, Drive Pinion Depth Gauge, Gauge Block Adapter, Gauge Tube and Pinion Depth Gauge.










5. NOTE: This step duplicates final pinion bearing preload.

Tighten the Adapter to achieve the specified rotational torque.

- Tighten to 2.2 Nm (20 lb-in).





6. NOTE: The Adapter must be offset to obtain an accurate reading.

Rotate the Adapter several half-turns to make sure of correct seating of the pinion bearings, and position the Adapter.





7. Install the Gauge Tube.

1. Position the Gauge Tube.

2. Install the 2 differential bearing caps.

3. Install the 4 differential bearing cap bolts.

- Tighten to 119 Nm (88 lb-ft).





8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.





9. NOTE: The same differential pinion bearing used in the shim selection procedure must be used in the final assembly of the axle.

Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer.





10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.





11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.





12. Lubricate the lip of the new drive pinion seal with grease.

13. Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal.





14. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing.





15. NOTE: The Drive Pinion Flange Installer must be used due to tight spline fit.

With the drive pinion in place in the axle housing, install the pinion flange using the Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer.





16. Position the new pinion nut and washer.





17. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.

Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.

- Refer to the torque specification for new pinion bearings in the Specifications.

- Tighten the pinion nut until the desired rotational torque is reached.





18. NOTE: If removed, press the speed sensor ring on with the differential ring gear.

Install the differential ring gear.

1. Place the differential ring gear on the differential assembly.

2. Hand-start 3 new ring gear bolts to align the holes in the differential ring gear and the differential assembly.

3. Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.

4. Press the differential ring gear into place.





19. Install the remaining 9 new differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).





20. Position the differential case in the rear axle housing.
- Install a shim on the left side as shown in the illustration.





21. NOTE: The bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the left side to make sure the left bearing is seated.

Install the left bearing cap and loosely install the 2 bearing cap bolts.





22. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.





23. Install the right side bearing cap with 2 bolts and tighten the 4 bolts.
- Tighten to 119 Nm (88 lb-ft).





24. Rotate the differential case to make sure it rotates freely.





25. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the ring gear backlash.
- If the backlash is within specification, go to Step 31.

- If a zero backlash condition occurs, go to Step 26.

- If the backlash is not within specification, go to Step 27.





26. If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Repeat Step 25.

27. NOTE: If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.









28. Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 119 Nm (88 lb-ft).





29. Rotate the differential several times to make sure the differential bearings are correctly seated.





30. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.





31. Remove the bearing caps and bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.

- Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.





32. Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 119 Nm (88 lb-ft).





33. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.





34. Apply marking compound and rotate the differential assembly 5 complete revolutions.

35. Verify an acceptable pattern check. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly and/or Drive/Propeller Shafts, Bearings and Joints.

36. Install the axle shafts. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly.

37. NOTICE: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the rear axle and the differential housing cover.

38. Apply a new, continuous bead of silicone to the differential housing cover as shown.





39. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone has properly cured.

Install the differential housing cover and the 12 differential housing cover bolts.

- For stamped steel housing covers, tighten alternately and evenly to 45 Nm (33 lb-ft).

- For cast aluminium housing covers, tighten alternately and evenly to 32 Nm (24 lb-ft).





40. NOTICE: For Traction-Lok(R) axles, first fill the axle with 118 ml (4 oz) of friction modifier or damage to the axle can occur.

NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Remove the filler plug, fill the axle to the level shown with axle lubricant and install the filler plug.

- Tighten to 30 Nm (22 lb-ft).





41. Position the driveshaft flange and align the index mark on the pinion flange.





42. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Install the 4 new driveshaft flange bolts.

- Tighten to 103 Nm (76 lb-ft).