Differential Ring and Pinion

Differential Ring And Pinion

















Removal

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury. Procedures

Remove the drive pinion flange seal. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal Service and Repair.

2. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

3. Remove and discard the 10 differential ring gear bolts.





4. NOTE: 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.





5. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.





6. Remove the drive pinion shaft oil slinger and the outer drive pinion bearing.

7. Install the Drive Pinion Thread Protector. Using a soft-faced hammer, drive the pinion assembly out of the axle housing.





8. Remove and discard the drive pinion collapsible spacer.





9. 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 Drive Pinion Bearing Cup Installer 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 Drive Pinion Bearing Cup Installer (inner) on the inner drive pinion bearing cup.

2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.

3. Install the Drive Pinion Bearing Cup Installer.





2. Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.





3. 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: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Assemble and position the Adapters for 205-S127.









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

Tighten the Adapter.

- Tighten to 2.2 Nm (20 lb-in).





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

Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings.





7. Install the Adapter.

1. Position the Adapter.

2. Install the 2 differential bearing caps.

3. Install the 4 differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).





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 Adapters.





9. Using the Drive Pinion Bearing Cone Installer and Bearing Oil Seal Plate with a shop press, drive the inner drive pinion bearing and the selected drive pinion bearing adjustment shim until they are 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. Using the Differential Side Bearing Installer, install the 2 new differential bearings.





14. Using 2 ring gear bolts as a guide, press the ring gear on the differential assembly.





15. Install the 10 new differential ring gear bolts. Tighten in 2 stages.
- Stage 1: Tighten to 60 Nm (44 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





16. Install the drive pinion seal and flange. For additional information, refer to Drive Pinion Flange and Drive Pinion Seal Service and Repair.

17. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

18. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury. Description and Operation

Repower the system.