Pinion Gear/Ring Gear - Installation

INSTALLATION

Special Tools:











NOTE: Do not attempt to install the inner and outer pinion bearing cups at the same time.

1. Use Pinion Bearing Cup Installer (1) to install the pinion head bearing cup (2).
2. Install the pinion tail bearing cup with pinion bearing cup Installer (1).





3. Determine the correct pinion depth and differential bearing preload Rear Axle - G648 Adjustments
4. Install the pinion depth shim (1) onto the pinion shaft (2).





5. Use an arbor press and Installer (1) to install the pinion head bearing (2).





6. Install the spacer (1) onto the pinion shaft.
7. Install the pinion into the case.






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 manufacturer'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.

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






NOTE: Apply a light coating of gear lube to pinion seal.

NOTE: Allow the pinion tail bearing to cool off to room temperature before installing the pinion seal.

9. Use pinion oil seal installer (1) to install the pinion seal (2).





10. Install the pinion flange (2).
11. Install the original pinion nut. Hold the pinion flange with flange holder (1) and tighten the pinion nut.
12. Remove and discard the original Pinion Nut.
13. Remove the Pinion Flange.
14. Install the pinion flange (2) and a new pinion flange nut. Tighten the pinion flange nut to 245 Nm (180 ft. lbs.).
15. Use an inch pound torque wrench to measure the turning torque of the pinion.
16. If the turning torque is too high, remove the selected shim, and install a larger shim on the pinion shaft, then verify the turning torque is correct. If the turning torque is too low, remove the selected shim, and install a smaller shim on the pinion, then verify the turning torque is correct.





17. Install the Ring Gear (2), and new Ring Gear Bolts (1). Tighten the bolts to 185 Nm (136 ft. lb.).





18. Measure end play of the differential, and determine the size of the required differential shims to get the correct differential side bearing preload and ring gear backlash. Rear Axle - G648 Adjustments
19. Install shim (1) in the cover.





20. Use Differential Bearing Cup Installer (2) and Universal Installer Handle (1) to install the differential side bearing cup (3) into the cover (3).





21. Install shim (1) in the case.





22. Use Differential Bearing Cup Installer and Universal Installer Handle to install the Differential Side Bearing Cup into the Case.
23. Install the Differential in the housing.





24. Temporarily install the cover (2), and the cover bolts (1).
25. Verify the ring and pinion gear contact pattern is within acceptable limits.
26. Tighten the cover bolts to 28 Nm (20 ft. lbs.).
27. Verify the total turning torque of the differential is within 2.5 to 6.0 Nm (22 - 53 in. lbs.). If necessary, adjust the size of the differential shims to bring the turning torque within specifications.
28. Install the rear axle assembly Installation.