Pinion Gear/Ring Gear - Installation

INSTALLATION

Special Tools:















NOTE: Pinion depth shims are located under the rear pinion bearing. Refer to Adjustments (Pinion Gear Depth) to select the proper thickness shim before installing pinion gear. If ring and pinion gears are reused, the pinion depth shim should not require replacement.

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





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





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





4. Install rear pinion bearing (4) on pinion (3) with Installer (2) and a press (1).





5. Install a new collapsible spacer (1) on pinion shaft (2).
6. Install pinion in housing.





7. Install front pinion bearing (1) on pinion shaft (2).





8. Install front pinion bearing oil slinger (1) on pinion shaft (2).





9. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer (1) and Handle (2).





10. Install pinion flange with Installer (1) Screw (2).





11. Install new pinion nut. Hold flange (1) with Holder (2) and tighten the nut to 217 Nm (160 ft. lbs.). Do not exceed minimum tighten torque 217 Nm (160 ft. lbs.).
12. With a torque wrench set at 352 Nm (260 ft. lbs.) tighten pinion nut until pinion end play is eliminated.





13. Rotate pinion several times to seat bearings and verify pinion (1) rotates smoothly.
14. Slowly tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Measure rotating torque frequently to avoid over crushing the collapsible spacer.
15. Measure pinion torque to rotate (PTTR) with an inch pound torque wrench (2). Pinion Torque To Rotate is:

- Original Bearings: 1.0 - 2.2 Nm (10 - 20 in. lbs.).
- New Bearings: 1.7 - 2.8 Nm (15 - 25 in. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.






16. Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
17. Invert differential case in the vise. Install new ring gear (2) bolts (1) and alternately tighten to 108 Nm (80 ft. lbs.).

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

18. Install differential in housing.





19. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench (2). This will verify the correct differential bearing preload.Total Torque to Rotate (TTTR) is Pinion Torque To Rotate (PTTR) plus:

- Gear Ratio 3.21: 0.53 - 0.87 Nm (4.6 - 7.7 in. lbs.)
- Gear Ratio 3.73: 0.45 - 0.75 Nm (3.9 - 6.6 in. lbs.)
If TTTR is high, decrease shim thickness equally on both sides of the differential and check TTTR again. If TTTR is low, increase shim thickness equally on both sides of the differential and check TTTR again.

20. Verify differential gear contact pattern.