Pinion Gear/Ring Gear - Installation

INSTALLATION

Special Tools:














1. Install rear pinion bearing cup in the carrier, with Installer (1) and Handle (2).





2. Install front pinion bearing cup in the carrier, with Installer (1) and Handle (2).






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

CAUTION: Pinion 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.






3. Heat rear pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on pinion (2) with tongs or welding gloves.

NOTE: Rear pinion bearing (1) can also be installed with Installer and a press.






4. Install select pinion bearing preload spacer (1) on pinion shaft (2).





5. Install pinion gear in carrier with preload spacer. Support pinion (3) in the carrier (1) or hold in place.





6. Heat front pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit).
7. Install front bearing (1) on the pinion shaft (2) with tongs or welding gloves.





8. Install pinion flange and original pinion nut.
9. Install Adapter (1) on pinion flange and bolt (2) in place.





10. Hold pinion flange with Holder (1) and Adapter (2).





11. Tighten original pinion nut to 937 Nm (689 ft. lbs.) with torque multiplier (1) and a torque wrench (2).





12. Measure pinion (1) torque to rotate (PTTR) with an inch pound torque wrench (2). Pinion torque to rotate is 2.3 - 4.5 Nm (20 - 40 in. lbs.). NOTE: To increase PTTR install a thinner spacer. To decreases PTTR install thicker spacer.
Spacers are available in sizes from 27.23 - 28.1 mm (1.072 - 1.1063 in.). A 0.0254 mm (0.001 in.) change in spacer thickness will change pinion torque to rotate approximately 3.3894 mm (30 in. lbs.).
NOTE: Pinion torque to rotate is measured without the pinion seal.






13. Install Adapter (1) on pinion flange and bolt (2) in place.





14. Hold pinion flange with Holder (1) and Adapter (2). Remove pinion nut with torque multiplier and a ratchet.





15. Bolt Puller (1) to Adapter and remove pinion flange.





16. Install new pinion seal with Installer (1) into housing (2).





17. Install pinion flange and new pinion nut.
18. Hold pinion flange with Holder (1) and Adapter (2).





19. Tighten pinion nut to 937 Nm (689 ft. lbs.) a with torque multiplier (1) and torque wrench (2).





20. Verify dowel pins are in case.
21. Lower ring gear onto the case dowel pins.
22. Install new ring gear (2) bolts (1).
23. Set case in a press with ring gear facing up. Press ring gear onto the case with an appropriate installer.

NOTE: Verify ring gear is square and flush to the case before pressing ring gear.

24. Tighten new ring gear bolts (1) to 286 Nm (210 ft. lbs.).





25. Install differential into carrier.
26. Install differential bearing cups and adjusters (1) into carrier.





27. Install differential bearing caps (1).






NOTE: Before tightening bearing caps, perform differential bearing preload and backlash adjustments.

28. Install new bearing cap (2) bolts and tighten to 190 Nm (140 ft. lbs.).





29. Install differential adjuster cotter pins (1) in bearing caps (2).