Differential Ring and Pinion

Differential Ring and Pinion














Special Tool(s)





Material

Removal
1. Remove differential carrier.





2. Using the special tools, remove the differential bearing.
^ Repeat for the other side.





3. Remove the 12 ring gear bolts.





4. CAUTION: Do not damage the ring gear bolt hole threads.

Insert a punch in the ring gear bolt holes and drive the differential ring gear off.

5. WARNING: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring only if damaged.

If necessary, remove the speed sensor ring.





6. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.





7. Remove the 4 driveshaft flange bolts.





8. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange.
^ Using mechanic's wire, position the driveshaft aside.





9. Using the special tool to hold the pinion flange, remove and discard the pinion nut.





10. Using the special tool, remove the pinion flange.





11. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed.





12. Remove the drive pinion shaft oil slinger.





13. Install the special tool, then use a soft-faced hammer to drive the pinion gear out of the outer drive pinion bearing and remove the pinion gear.





14. Using a brass drift, remove the drive pinion bearing cups by tapping alternately on opposite sides of the drive pinion bearing cups.

Installation





1. Position the special tools and the inner and outer drive pinion bearing cups in their respective bores.
1 Place the special tool on the outer drive pinion bearing cup.
2 Place the special tool on the inner drive pinion bearing cup.
3 Install the special tool.





2. Tighten the special tool to fully seat the differential drive pinion bearing.





3. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.

Make sure the differential pinion bearing cups are correctly seated.








4. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Install the new drive pinion bearings and special tools as shown.





5. Tighten the special tool to the specified rotational torque.
^ Tighten to 2.2 Nm (20 inch lbs.).





6. NOTE: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings, then position the special tool.





7. Install the special tool.
1 Position the special tool.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in the final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
^ After the correct drive pinion bearing adjustment shim thickness has been determined, remove the special tools.





9. Using the special tools, press the drive pinion bearing and drive pinion bearing adjustment shim until they are firmly seated on the pinion gear.





10. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.





11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
12. Lubricate the new drive pinion seal with grease.





13. CAUTION: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.

Using the special tool, install a new drive pinion seal.
14. Lubricate the pinion flange splines with grease.





15. Install the pinion gear in the pinion gear bore from inside the axle housing.





16. Using the special tool, install the pinion flange.





17. Position the new pinion nut.





18. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.

CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (inch lbs. ) torque wrench.

Using the special tool to hold the pinion flange, tighten the pinion nut.
^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
^ Install a Nm (inch lbs.) torque wrench on the pinion nut.
^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the drive pinion bearing preload specification is obtained.





19. Press the LH and RH differential bearing on the differential assembly.





20. NOTE: If removed, press the speed sensor ring on with the differential ring gear.

Install the differential ring gear.
1 Place the differential ring gear on the differential assembly.
2 Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
3 Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4 Press the differential ring gear into place.





21. Install the 12 differential ring gear bolts.
^ Apply stud and bearing mount to the differential ring gear bolts.
^ Tighten to 150 Nm (111 ft. lbs.).





22. Install the differential assembly in the axle housing.





23. Install a differential bearing shim on the LH side.





24. CAUTION: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.





25. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.





26. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





27. Rotate the differential assembly to make sure it rotates freely.





28. NOTE: If ring gear backlash is within specification, go to Step 32.

Using the special tools, measure ring gear backlash.








29. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
^ If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.





30. Rotate the differential assembly several times to make sure the differential bearings are seated.





31. Using the special tools, recheck the ring gear backlash.





32. Remove the differential bearing cap bolts and differential bearing caps.





33. NOTE: To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Using the special tool, install the differential bearing shims.





34. Install the differential bearing caps and differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
35. Apply marking compound and rotate the differential assembly 5 complete revolutions.
36. Verify an acceptable pattern check.
37. Install the axle shafts.





38. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.
39. Apply a new, continuous bead of sealant to the differential housing cover.





40. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.

Install the differential housing cover and the differential housing cover bolts.
^ Tighten to 45 Nm (33 ft. lbs.).





41. CAUTION: For Traction-Lok axles, first fill the axle with 118 ml (4 ounces) of friction modifier.

NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fill the axle to the level shown with axle lubricant and install the filler plug.
^ Tighten to 30 Nm (22 ft. lbs.).





42. Position the driveshaft and align the index mark on the pinion flange.





43. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Install the driveshaft flange bolts.
^ Tighten to 103 Nm (76 ft. lbs.).