Differential Ring and Pinion

Differential Ring And Pinion

Special Tools (2 Of 5):

Special Tools (2 Of 5):

Special Tools (3 Of 5):

Special Tools (4 Of 5):

Special Tools (5 Of 5):

Material:

Removal

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

2. Using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Collets, Differential Carrier Bearing Retaining Ring, Bearing Tube Remover/Installer and Bearing Tube Remover Screw, remove the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.






3. NOTE: Use a vise with brass jaws or wood blocks.

Place the differential carrier in a vise.

4. NOTE: Whenever removing the differential ring gear bolts, always install new Grade 9 differential ring gear bolts.

Remove and discard 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.






5. Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 differential ring gear bolts. Remove the differential ring gear.






6. If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.






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






8. Remove and discard the 4 driveshaft flange bolts.






9. NOTICE: The driveshaft flange fits tightly on the pinion flange. Using a suitable tool, pry only in the area shown to disconnect the driveshaft flange or damage to the driveshaft may occur.

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

NOTE: Do not allow the driveshaft to hang unsupported.

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 shaft locknut and washer.






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






12. NOTE: There are drive pinion bearing preload shims on the splined-end of the pinion shaft. These drive pinion bearing preload shims can stick to the pinion shaft, the pinion bearing or they can fall out of the axle housing. Collect and keep the drive pinion bearing preload shims for reassembly.

Using the Drive Pinion Thread Protector, drive the pinion from the outer pinion bearing and remove it through the rear of the axle housing.






13. Using the Slide Hammer and Bushing Remover, remove and discard the drive pinion seal.






14. Remove the drive pinion oil slinger, the outer drive pinion bearing and the pinion preload adjustment shims.

15. NOTICE: Do not nick the axle housing bore or damage to the component may occur.

Using the Rear Wheel Hub Bearing Cup Remover and Handle, remove the outer pinion bearing cup.






16. Using the Drive Pinion Inner Bearing Remover and Handle, remove the inner pinion bearing cup.






Installation

1. Position the inner and outer pinion bearing cups and the Rear Axle Drawbar and Drive Pinion Bearing Cup Installers in their respective axle housing bores.

1. After placing the inner and outer pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner pinion bearing cup.

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

3. Install the Rear Axle Drawbar.






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






3. NOTE: If the feeler gauge can fit between a pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, remove and reseat the pinion bearing cup.

Check that the pinion bearing cups have seated correctly in their bores.






4. NOTE: If removed, install the anti-lock speed sensor ring.

Start 2 new ring gear bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.






5. Press the anti-lock speed sensor ring and differential ring gear on the differential carrier. The differential carrier flange acts as a pilot for the anti-lock speed sensor ring.






6. Install the 10 remaining ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).






7. NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.

Place the 0.762 mm (0.030 in) inboard shim and the Dummy Bearing Set on the differential carrier hubs. Position the differential carrier into the axle housing.






8. NOTE: Use a Dial Indicator Gauge with a minimum travel capability of 5.08 mm (0.200 in).

Mount the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge as shown. Locate the tip of Clutch Housing Gauge on the flat surface of one of the differential ring gear bolts.






9. NOTE: Repeat this step and the following step until the same reading appears on the Dial Indicator Gauge each time. Record the reading. This is the total differential outboard bearing spacer thickness required, less preload. The final calculation occurs later during assembly.

Force the differential carrier as far as possible toward the Dial Indicator Gauge. With force still applied, zero the Dial Indicator Gauge.






10. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.






11. After making sure the reading is correct, remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and the differential carrier from the axle housing. Do not remove the Dummy Bearing Set bearings or the bearing shims from the differential carrier at this time.

12. NOTE: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

NOTE: Apply a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.

1. Position the Adapter.
2. Position the Alignment Adapter.
3. Position the inner pinion bearing.
4. Position the Drive Pinion Depth Gauge/Aligner.
5. Position the Adapter.
6. Position the outer pinion bearing.
7. Thread on the Handle.






13. Install the Gauge Tube.

1. Install the differential bearing caps.

2. Install the differential bearing cap bolts.

- Tighten to 108 Nm (80 lb-ft).






14. Inspect the drive pinion bearing preload shim for damage. Discard it if necessary. New drive pinion bearing preload shims are available in the thickness shown in the following chart.

Available Inner Drive Pinion Bearing Shims






15. NOTE: Use a feeler gauge or flat, clean drive pinion position shim as a measuring device.

NOTE: Do not attempt to force the gauge or drive pinion position shim between the Adapter and Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shim, measure between the Gauge Tube and Adapter. Record the measurement.






16. Notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures. If so equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.
- For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.

17. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

NOTE: Position the selected pinion depth shim on the pinion shaft between the inner bearing and the pinion head.

Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer and a suitable press, install the pinion bearing.






18. Position the original pinion bearing preload shims on the pinion and install the pinion gear in the pinion gear bore from the rear of the housing.

19. Install the outer pinion bearing and drive pinion oil slinger.

20. NOTICE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.

Using the Drive Pinion Flange Installer, install the pinion flange.






21. Use the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning while installing the old washer and the pinion shaft locknut.
- Tighten to 637 Nm (470 lb-ft).






22. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.3-4.5 Nm (20-40 lb-in).
- To increase the drive pinion bearing preload, remove drive pinion bearing preload shims. To decrease the drive pinion bearing preload, add drive pinion bearing shims.






23. While using a the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning, remove and discard the old washer and pinion shaft locknut.






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






25. NOTE: If the drive pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new drive pinion seal must be installed.

Using the Drive Pinion Oil Seal Installer, drive the pinion seal into the housing.

- Coat the pinion seal (rubber lips) with axle lubricant.






26. NOTE: The pinion flange must never be hammered on or installed with power tools.

Using the Drive Pinion Flange Installer, install the pinion flange.






27. Using the Drive Pinion Flange Holding Fixture, prevent the pinion flange from turning while installing the new washer and pinion shaft locknut.
- Tighten to 637 Nm (470 lb-ft).






28. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 0.6 Nm (5 lb-in) higher with the new pinion seal installed.






29. Position the differential carrier assembly with the Dummy Bearing Set and inner bearing shims in the axle housing. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.






30. Force the differential case away from the drive pinion. With force still applied, set the Dial Indicator Gauge to zero.






31. NOTE: Repeat this step and the preceding step until the same reading appears on the Dial Indicator Gauge each time. This is the differential outboard bearing shim thickness increase necessary between the differential bearing and the LH side of the differential case.

Force the differential ring gear into mesh with the pinion to obtain the Dial Indicator Gauge reading. Record the reading.






32. Remove the differential case from the differential housing.






33. Remove the Dummy Bearing Set from the differential case.
- Make sure the inner bearing shims remain on the differential carrier hubs.

34. Install the original outboard spacers in the side from which they were removed.






35. Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.






36. Using the Differential Carrier Bearing Installer and Differential Carrier Bearing Step Plate, install the differential bearing.

1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.

2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.






37. Assemble the differential bearing cups to the differential bearings.

38. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.

39. Determine the correct outboard spacer thickness and place it on the differential case hub on the RH side.
- To determine the correct spacer thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness spacer to place on RH side of the housing.

40. NOTICE: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification.

- Use a rawhide hammer to seat the differential into the differential housing pocket.






41. NOTE: Match the mating letters as noted during disassembly.

Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.

- Tighten to 108 Nm (80 lb-ft).






42. Confirm the total preload.
- Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential carrier installed) with new bearings installed as recommended by the following:

- 3.54 and 3.73 = 0.9 Nm (8 lb-in)
- 4.10 and 4.56 = 0.8 Nm (7 lb-in)
- 4.63 and 5.13 = 0.8 Nm (7 lb-in)

- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.






43. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.






44. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to Differential Assembly and/or Axle Shaft Assembly and/or Drive/Propeller Shafts, Bearings and Joints.

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

46. NOTE: Align the index marks made during removal.

Position the driveshaft flange on the pinion flange and install the 4 new bolts.

- Tighten to 100 Nm (74 lb-ft).






47. NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant to the differential housing cover as shown.






48. Install the differential housing cover and the 10 bolts.
- Tighten alternately and evenly to 45 Nm (33 lb-ft).

49. NOTE: If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.

Fill the axle with the specified type and amount of lubricant.