Installation

INSTALLATION




1. Install selected pinion depth shim into housing.




2. Press pinion head bearing cup into housing using Handle C-4171 (1) and Installer C-4310 (2).




3. Press pinion tail bearing cup into housing using Handle C-4171 (1) and Installer D-146 (2).




4. Press new pinion head bearing (2) onto pinion shaft using Installer C-3095-A (1).




5. Install washers (2) and new collapsible spacer (1) to pinion shaft.




6. Install pinion shaft (1) into housing and support on press table atop Installer 8255 (2). Ensure pinion gear face is centered atop Installer 8255.




7. Using Installer C-3095-A (1), press on new pinion tail bearing (2).




8. Install new pinion seal (1) into position.




9. Press pinion seal into housing using Installer 9231A (1).




10. Lightly lubricate pinion flange seal with axle lubricant for flange installation.
11. Align index marks and press pinion flange (2) on using Installer C-3095-A (1).




12. Install new pinion flange nut by hand.
13. Hold pinion flange with Flange Wrench C-3281 (1). Using a deep 41 mm socket, tighten pinion flange nut to an initial torque of 203 Nm (150 ft. lbs.).




14. Rotate pinion flange to ensure bearing is properly seated.
15. Measure pinion rotating torque using suitable torque wrench (1). Pinion rotating torque should be 215-245 N. cm (19-22 in. lbs.).
16. If pinion rotating torque exceeds the specified range, the pinion shaft must be removed and the crush sleeve replaced.




17. If pinion rotating torque is below the specified range, increase nut torque by 7 Nm (5 ft. lbs.) increments and recheck turning torque until rotating torque is within range.




18. Stake pinion flange nut (1) using hammer and suitable punch.




19. Install ring gear to differential case. Loosely install new ring-gear-to-differential case bolts.
20. Torque all ring gear-to-case bolts to 85 Nm (64 ft. lbs.)




21. Install differential and reassemble axle assembly.