Pinion Gear/Pinion Gear

Fig 1: Rear Pinion Bearing Cup

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Install oil baffle in rear bearing cup bore then install rear bearing cup with Installer C-4308 (1) and Handle C-4171 (2).

Fig 2: Front Bearing Cup Installer
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Install front bearing cup with Installer D-146 (1) and Handle C-4171 (2).

Fig 3: Front Pinion Bearing
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Install front pinion bearing (1) into the housing.

Fig 4: Oil Slinger
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Install front pinion bearing oil slinger (1) into the housing.

Fig 5: Seal Installer 8681
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Apply a light coating of gear lubricant on pinion seal lip and install seal with Installer 8681 (1) and Handle C-4171 (2).

Fig 6: Pinion Depth Shim
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Install pinion depth shim (1) on pinion shaft (2).

Fig 7: Rear Pinion Bearing
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Install rear pinion bearing (4) on pinion gear (3) with Installer C-4040 (2) and a press (1).

Fig 8: Collapsible Spacer
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Install new collapsible spacer (1) on pinion shaft (2) and install pinion into the housing.

Fig 9: Flange Installer
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Install pinion flange (1) with Installer 8112 (2) and Cup 8109.

Fig 10: Flange Holder
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Install new pinion nut.
With Flange Wrench C-3281 (2) and torque wrench tighten pinion nut to 217 N.m (160 ft. lbs.).

Fig 11: Torque To Rotate
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Using Flange Wrench C-3281 and torque wrench set at 542 N.m (400 ft. lbs.). Slowly tighten the nut in 6.8 N.m (5 ft. lb.) increments until the pinion torque to rotate is achieved. Measure pinion (1) torque to rotate with an inch pound torque wrench (2) frequently to avoid over crushing the collapsible spacer.
Pinion Torque To Rotate (PTTR) is:
1. Original Bearings: 1.13 - 2.26 N.m (10 - 20 in. lbs.).
2. New Bearings: 1.7 - 3.4 N.m (15 - 30 in. lbs.).
CAUTION: If more than 542 N.m (400 ft. lbs.) torque is required to crush the collapsible spacer, the spacer is defective and must be replaced. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions may result in damage.

Fig 12: Ring Gear
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Install ring gear with new ring gear bolts (1) and alternately tighten to 108 N.m (80 ft. lbs.).
CAUTION: Never reuse ring gear bolts. Failure to follow these instructions may result in damage.
Install differential case in to axle housing.

Fig 13: Torque To Rotate
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Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shafts. This will verify differential bearing preload.
Total Torque To Rotate is: Pinion Torque To Rotate (PTTR) plus 0.79 - 1.24 N.m (7 - 11 in lbs.).

NOTE: If TTTR is too high, decrease shim thickness equally from both sides of the differential and check TTTR again. If TTTR is too low, increase shim thickness equally to both sides of the differential and check TTTR again.