Reassembly (Pinion Assembly)

Lubricate all parts with hypoid gear oil. Using press and Pinion Bearing Installer (J-24433), press pinion inner bearing onto pinion. Using Driver Handle (J-8092) and Outer Bearing Cup Installer (J-8608), install outer bearing cup. Using driver and Inner Bearing Cup Installer (J-24432), install inner cup.
Install new collapsible spacer to pinion. Insert pinion into pinion cage. Press outer bearing onto pinion shaft. Install new pinion oil seal using driver handle and Seal Installer (J-24434). Install pinion flange oil deflector and pinion flange.
Install pinion washer and new pinion nut. Place pinion cage in soft-jawed vise. Install Companion Flange Holder Set (J-8614-01) to pinion flange. While rotating pinion gear, tighten pinion nut until there is no end play left at pinion. Rotate pinion several times and check pinion preload. Tighten pinion nut in small steps, rotating pinion between adjustments until preload is adjusted to specification. See AXLE ASSEMBLY SPECIFICATIONS table.
NOTE: If pinion preload limits are exceeded, pinion will have to be removed and a new collapsible spacer have to be installed.
If reinstalling original ring and pinion gears, use new pinion shims of same number and thickness as those removed. If installing new gears, compare pinion depth code number of new pinion gear with that of original pinion gear. From these 2 codes, determine correction factor by referring to PINION DEPTH CODES table.
Combine correction factor with thickness of new shim pack. Place new shim pack onto carrier housing. Install new pinion pilot bearing into axle housing using driver handle and Pilot Bearing Installer (J-34943). Install pinion cage to axle housing. Tighten 6 cage retaining bolts to specification in a crosswise sequence. See TORQUE SPECIFICATIONS table.