Pinion Gear/Ring Gear - Installation

INSTALLATION





1. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (2).





2. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).





3. Install pinion front bearing (1) in housing.





4. Install pinion front bearing oil slinger (1) in housing.





5. Install pinion seal with Installer 8889 (1).





6. Install pinion depth shim (1) on pinion gear (2).






WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.






7. Heat rear pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit).
8. Install rear pinion bearing (1) on pinion gear (2) with tongs or welding gloves.

NOTE: Rear pinion bearings can be installer with Installer 6448A and a shop press.






9. Install a new collapsible spacer (1) on pinion shaft (2).





10. Install pinion gear in housing.
11. Install pinion yoke (1) with Installer C-3718 (2).





12. Install yoke washer and new nut. Use Holder 6719A (1) to hold the yoke (2) and tighten nut to 298 Nm (220 ft. lbs.).
13. Using yoke Holder 6719A and a torque wrench set at 380 Nm (280 ft. lbs.) tighten pinion nut until bearing end play is taken up.





14. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.
15. Check pinion (2) torque to rotate with an inch pound torque wrench (1). Pinion torque to rotate should be:
- Original Bearings - 1 to 3 Nm (10 to 20 in. lbs.).
- New Bearings - 2 to 5 Nm (15 to 35 in. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion bearing preload torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed.






16. Install new ring gear bolts and alternately tighten to 122-150 Nm (90-110 ft. lbs.).

CAUTION: Never reuse ring gear bolts. Failure to follow these instructions will result bolt fracture, causing extensive damage.

17. Install differential in housing and verify gear mesh and contact pattern. Refer to Adjustments for procedure.
18. Install rear axle assembly.