Ring and Pinion

GEAR-PINION/RING

REMOVAL

NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.

1. Mark pinion flange and propeller shaft for installation alignment.
2. Disconnect propeller shaft from pinion flange and remove propeller shaft.
3. Remove axle shafts.
4. Remove differential from housing.
5. Place differential case in a vise with soft metal jaw protectors
6. Remove bolts holding ring gear to differential case.





7. Drive ring gear (2) from differential case (1) with a soft hammer (3).





8. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut and washer.





9. Remove pinion flange (1) from pinion with Pinion Flange Puller 8992 (2).





10. Remove pinion gear (1) from housing with Pinion Driver 8976 (2) and a hammer.

NOTE: Thread drive on shaft until it bottoms out.

11. Remove pinion seal with a slide hammer or pry bar.
12. Remove and discard front pinion bearing.
13. Remove collapsible spacer from the pinion shaft.





14. Remove rear pinion bearing with Puller C-293-PA (1) and Adapters 8879 (4).
15. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims.
16. Remove front pinion bearing cup from the housing with a punch and hammer and discard cup.
17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is replaced.

INSTALLATION





1. Install front pinion bearing cup with Installer D-146 (1) and Handle C-4171 (2).





2. Install rear pinion bearing cup with Installer 8886 (1) and Handle C-4171 (2), if bearing is replaced.





3. Install pinion depth shim (1) on the pinion gear (2) shaft.





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





5. Install new collapsible spacer (1).
6. Lubricate pinion and bearings.





7. Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8982 (1).





8. Install new pinion seal with Installer 8882 (2) and Handle C-4171 (1).
9. Apply a light coat of teflon sealant to the pinion flange splines.
10. Hold pinion and lightly tap the pinion flange onto the pinion shaft, until a few threads are showing.
11. Install pinion flange washer and new pinion nut.
12. Hold pinion flange with Flange Wrench 8979 and tighten pinion nut until end play is taken up.
13. Rotate pinion several times to seat bearings.





14. Measure pinion (1) rotating torque with an inch pound torque wrench (2). Tighten pinion nut in small increments until pinion rotating torque is:
^ New Pinion Bearings: 1.7 - 2.8 Nm (15 - 25 inch lbs.)
^ Original Pinion Bearings: 1.1 - 2.2 Nm (10 - 20 inch lbs.)

15. Rotate pinion several times then verify pinion rotating torque again.
16. Position the ring gear on differential case and start two new ring gear bolts.
17. Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear.
18. Torque ring gear bolts to 140 Nm (103 ft. lbs.).
19. Install differential in housing.
20. Measure final rotating torque with an inch pound torque wrench. The final pinion rotating torque plus differential case bearing preload is:
^ New Bearings: 3.4 - 5.6 Nm (30 - 50 inch lbs.)
^ Original Bearings: 2.8 - 5.1 Nm (25 - 45 inch lbs.)

21. Install axle shafts.
22. Verify ring gear backlash and gear contact pattern.
23. Install the propeller shaft with the reference marks aligned.
24. Install differential cover with gasket and tighten to 40 Nm (30 ft. lbs.).
25. Fill differential with fluid and tighten fill plug to 32 Nm (24 ft. lbs.).