Pinion Gear/Ring Gear

Fig 1: Rear Bearing Cup

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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-129 (1) and Handle C-4171 (2).

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

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

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

Fig 6: Pinion Depth Shim
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Install pinion depth shims (1) on the pinion 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 shaft (3).

Fig 9: Flange Installer C-3718
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Install pinion gear into the housing.
Install pinion flange (1) with Installer C-3718 (2).

Fig 10: Flange Wrench 6958
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Install pinion washer and a new nut. Hold pinion flange with Spanner Wrench 6958 and tighten pinion 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 specification is achieved.

Fig 11: Torque To Rotate
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Measure Pinion Torque To Rotate (1) (PTTR) 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 to 2 N.m (10 to 20 in. lbs.)
2. New Bearings - 2 to 4.5 N.m (20 to 40 in. lbs.)
Fig 12: Ring Gear
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Install new ring gear bolts (1) and alternately tighten to 136 N.m (100 ft. lbs.) for 7/16 inch bolts or 183 N.m (135 ft. lbs.) for 1/2 inch bolts.
CAUTION: Never reuse ring gear bolts, the bolts can fracture causing extensive damage. Failure to these instruction may result in damage.
Install differential in axle housing and verify gear backlash, mesh and contact pattern.

Fig 13: Torque To Rotate
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Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shafts.
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.