Installation

INSTALLATION





NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting.

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




2. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).
3. Lubricate and install front pinion bearing.




4. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B (3) and Handle C-4735 (1).




5. Install proper thickness depth shim (1) on the pinion gear (2).




6. Install rear bearing (4) on pinion gear (3) with Installer C-3095-A (2) and a press (1).




7. Install new collapsible spacer (1) on the pinion shaft.
8. Lubricate rear pinion bearing and install the pinion into the housing.




9. Install companion flange with Installer C-3718 and Holder 6719A.
10. Install bolts into two of the threaded holes in the companion flange 180� apart.
11. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719A is held to the flange.
12. Install pinion washer and a new pinion nut. The convex side of the washer must face outward.
13. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.).

NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point.




14. Rotate pinion several times to ensure pinion bearings are seated.
15. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Measure pinion rotating torque frequently to avoid over-crushing the collapsible spacer.

Pinion Torque To Rotate is:

- Original Bearings: 1 - 2.2 Nm (10 - 20 in. lbs.)
- New Bearings: 1.7 - 4 Nm (15 - 35 in. lbs.)

If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved.


CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded a new collapsible spacer must be installed. Failure to follow these instruction will damage the axle.




16. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
17. Invert the differential case in the vise.
18. Install new ring gear bolts (2) and alternately tighten to 157 Nm (115 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in bolts fracture.

19. Install differential in housing and verify gear mesh, backlash and contact pattern.