Installation

Fig. 12:

1. Install a new collapsible preload spacer on pinion shaft.
2. If pinion gear was removed, install pinion gear in housing.
3. Install pinion front bearing, if necessary.

Fig. 13:

4. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer D-163 and Handle C-4171.
5. Inspect pinion seal excluder. Replace if necessary, and install pinion seal excluder on pinion yoke.

Fig. 14:

6. Install yoke with Screw 8112, Cup 8109, and Holder 6958.
7. If the original pinion bearings are being used, install differential assembly and axle shafts, if necessary.

NOTE: If new pinion bearings were installed, do not install the differential assembly and axle shafts until after the pinion bearing preload and rotating torque are set.

8. Install the yoke washer and a new nut on the pinion gear. Tighten the pinion nut until there is zero bearing end-play.
9. Tighten the nut to 271 Nm (200 ft. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

10. Using yoke holder 6958, a short length of 1 in. pipe, and a torque wrench set at 474 Nm (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up.

NOTE: If more than 474 Nm (350 ft. lbs.) of torque is necessary to remove the bearing end play, the collapsible spacer is defective and must be replaced.

Fig. 15:

11. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.
12. Check rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be:
- Original Bearings-The reading recorded during removal, plus an additional 0.56 Nm (5 inch lbs.).
- New Bearings-2 to 5 Nm (15 to 35 inch lbs.).
13. Install differential assembly and axle shafts, if necessary.
14. Align marks made previously on yoke and propeller shaft and install propeller shaft.
15. Align marks made previously on the driveshafts and axle shafts and install driveshafts.
16. Add gear lubricant, if necessary. Refer to Lubricant Specifications for lubricant requirements.
17. Install skid plate, if equipped.
18. Lower vehicle.