Pinion/Ring Gear

Fig 1: Rear Pinion Bearing Cup

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

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

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

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

Fig 5: Seal Installer 8681
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Apply a light coating of gear lubricant on pinion seal lip. 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 gear shaft (2).

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

Fig 8: Removing Collapsible Preload Spacer
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Install collapsible spacer (1) on pinion gear (3).

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

Fig 10: Flange Holder
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Install new nut on the pinion gear. Hold pinion flange (1) with Flange Wrench C-3281 (2) and tighten nut to 217 N.m (160 ft. lbs.).
Set torque wrench to 271 N.m (200 ft. lbs.) and tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until Pinion Torque To Rotate (PTTR) specification is achieved.

Fig 11: Torque To Rotate
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Measure Pinion Torque To Rotate (1) after each 6.8 N.m (5 ft. lbs.) increment with an inch pound torque wrench (2).
Pinion Torque To Rotate is:
1. Original Bearings: 1 - 2 N.m (10 - 20 in. lbs.)
2. New Bearings: 2 - 4.5 N.m (20 - 40 in. lbs.)
Fig 12: Ring Gear
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Install ring gear with new ring gear (2) bolts (1) and alternately tighten to 136 N.m (100 ft. lbs.).
CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction may result in damage.

Fig 13: Indicator Switch
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Install Tru-Lok indicator switch (1) into differential housing (2).
Install differential case into axle housing.

Fig 14: 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 shaft. This will verify differential bearing preload.
Total Torque To Rotate is: Pinion Torque To Rotate 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.