Differential Ring and Pinion

Differential Ring and Pinion








Special Tool(s)

Removal
1. Remove the differential case.





2. Remove the 10 differential ring gear bolts.






3. CAUTION: Do not damage the differential ring gear bolt hole threads.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
4. Remove the drive pinion flange and drive pinion seal.
5. Remove the drive pinion shaft oil slinger and the outer drive pinion bearing.





6. Install the special tool. Using a soft-faced hammer, drive the pinion assembly out of the axle housing.





7. Remove and discard the drive pinion collapsible spacer.





8. Using the special tool, remove the inner drive pinion bearing.






9. NOTE: Do not remove the drive pinion bearing Cups from the housing unless the drive pinion bearing cups are damaged.

Using a brass drift, remove the drive pinion bearing cups by tapping alternately on opposite sides of the drive pinion bearing cups.

Installation





1. Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
1. After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
2. Place the special tool (outer) on the outer drive pinion bearing cup.
3. Install the special tool.





2. Tighten the special tool to seat the drive pinion bearing cups into their bores.






3. CAUTION: Whenever new drive pinion bearing cups are installed, new drive pinion bearings must also be installed.

NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.

Make sure the drive pinion bearing cups are correctly seated in their bores.






4. NOTE: Apply only a light oil film on the drive pinion bearings before assembling the tools.

Assemble and position the special tools.






5. NOTE: This step duplicates final drive pinion bearing preload.

Tighten the special tool.
^ Tighten to 2.2 Nm (60 inch lbs.).






6. NOTE: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.





7. Install the special tool.
1. Position the special tool.
2. Install the differential bearing caps.
3. Install the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).






8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
^ After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.





9. Using the special tool, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.





10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.





11. Install the drive pinion assembly into the axle housing.
12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
13. Install the drive pinion flange and drive pinion seal.





14. Press the differential ring gear on the differential assembly.






15. NOTE: Apply stud and bearing mount to the differential ring gear bolts.

Install the differential ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

16. Install the differential case.