Installation

INSTALLATION





NOTE: Ring and pinion gears are a matched set. Do not replace 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-130 (1) and Handle C-4171 (2).




3. Install front pinion bearing and oil slinger if equipped.
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 pinion gear (2).




6. Install rear bearing (4) and slinger if equipped, on pinion gear (3) with Installer 6448A (2) and a press (1).




7. Install a new collapsible spacer (1) on the pinion gear shaft.
8. Lubricate rear pinion bearing (2) and install pinion into the housing.




9. Install companion flange with Installer C-3718 and Holder 6719A (2).
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 companion flange washer and new pinion nut.
13. With a torque wrench (3) tighten pinion nut 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. Measure pinion torque to rotating (1) with an inch pound torque wrench (2). Measure pinion torque to rotating frequently to avoid over 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.




15. Position exciter ring on differential case. With a brass drift slowly and evenly tap the exciter ring into position.
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 122 Nm (90 ft. lbs.).

CAUTION: Never reuse the bolts that held the ring gear to the differential case. Failure to follow these instructions will result in fracture bolts can causing extensive damage.

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