Drive Pinion
IN-VEHICLE REPAIRSpecial Tools And equipment Part 1 Of 3:
Special Tools And equipment Part 2 Of 3:
Special Tools And equipment Part 3 Of 3:
Special Tool(s)
Material:
Material
Removal
1. Remove the differential case.
2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange.
Remove the pinion flange.
3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer.
4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal.
5. Remove the rear axle drive pinion shaft oil slinger.
6. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer pinion bearing and remove it through the rear of the differential housing.
7. Remove the outer pinion bearing.
8. Remove the drive pinion collapsible spacer and discard it.
9. Using the special tool and a suitable press, remove the pinion bearing.
10. NOTE: Do not remove the pinion bearing cups from the differential housing unless the cups are damaged.
Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the cups.
Installation
Using special tool 205-024
NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to using special tools 205-153, 205-024, and 205-D055 in this procedure for an alternate method.
1. Position the special tools and the inner and outer pinion bearing cups in their respective bores.
1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
2.l Place the special tool on the outer bearing cup.
3. Install the special tool.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
3. CAUTION: Always install new pinion bearings when installing new pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
Check that the cups have seated correctly in their bores.
4. Using the special tools, drive the outer pinion bearing cup into the differential housing.
Using special tools 205-153, 205-024, and 205-D055
NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps.
5. Using the special tools, drive the inner pinion bearing cup into the differential housing.
6. CAUTION: Always install new pinion bearings when installing new pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
Check that the cups have seated correctly in their bores.
Setting pinion depth
Part 1 Of 2:
Part 2 Of 2:
7. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
Assemble and position the following in the differential housing.
8. NOTE: This step duplicates final pinion bearing preload.
Tighten the special tool to the specification shown.
9. NOTE: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and position the special tool as shown.
10. Install the special tool.
1. Position the special tool.
2. Install the bearing caps.
3. Install the bolts.
11. CAUTION: Use only flat, clean drive pinion bearing adjustment shims.
CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the special tools. A slight drag indicates correct shim selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ After determining the correct shim thickness, remove the special tools.
12. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on the drive pinion. Using a suitable press and the special tools, press the pinion bearing until it seats firmly on the pinion.
13. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
14. CAUTION: Installation without the correct tool can result in early seal failure.
Install a new rear axle drive pinion seal.
1. Install the front pinion bearing.
2. Install the rear axle drive pinion shaft oil slinger.
3. Install the rear axle drive pinion seal on the special tool.
15. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal.
NOTE: Coat the rear axle drive pinion seal lips with grease.
Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place.
16. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore.
17. Lubricate the pinion flange splines with rear axle lubricant.
18. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
19. Using the special tool, install the pinion flange.
20. Position the new nut.
21. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
Use the special tool to hold the pinion flange while tightening the nut.
^ Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
^ For new pinion bearings, tighten the nut to specification.
^ For used pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification.
^ For used pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.
Final assembly
22. Install the differential case in the differential housing.
23. Position the driveshaft flange on the pinion flange with the index marks aligned.
24. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock.
CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To mark sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.
Install the bolts.