Drive Pinion
Drive Pinion
Special Tools (1 Of 3):
Special Tools (2 Of 3):
Special Tools (3 Of 3):
Material:
Removal
1. Remove the differential case.
2. Remove the rear driveshaft.
3. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.
Using a suitable tool to prevent the flange from turning, remove the pinion lock nut and washer.
4. Using the special tool, remove the pinion flange.
5. NOTE: There are drive pinion preload shims on the spline end of the pinion. These shims can stick to the pinion, the pinion bearing or they can fall out of the differential housing. Collect and keep the shims for reassembly.
Using a soft faced hammer and the special tool, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
6. Using the special tools, remove and discard the pinion seal.
7. CAUTION: Do not nick the differential housing bore.
Using the special tools, remove the outer pinion bearing cup.
8. Using the special tools, remove the inner pinion bearing cup.
9. Using the special tools, remove the inner pinion bearing.
10. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
Remove the oil slinger, if equipped, and the drive pinion position shim.
Installation
1. Position the special tools and the inner and outer pinion bearing cups in their respective housing bores.
1 After placing the inner outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2 Place the special tool (outer) on the outer pinion bearing cup.
3 Install the special tool.
2. Tighten the special tool to seat the pinion bearing cups into their bores.
3. CAUTION: Always install new pinion bearings when installing new bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
Check that the cups have seated correctly in their bores.
4. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
NOTE: Apply a light oil film on the pinion bearings before assembling the tools.
Assemble and position the following in the differential housing.
1 Position the special tool.
2 Position the special tool.
3 Position the inner pinion bearing.
4 Position the special tool.
5 Position the special tool.
6 Position the outer pinion bearing.
7 Thread on the special tool.
Part 1:
5. NOTE: This step simulates pinion bearing preload.
Using a Nm (inch-pound) torque wrench, tighten the Handle to specification.
Part 2:
6. NOTE: Offset the Gauge Block to obtain an accurate reading.
Rotate the Gauge Block several half turns to make sure the pinion bearings are correctly seated and position the Gauge Block.
7. Install the special tool.
1 Position the special tool.
2 Install the bearing caps.
3 Install the four bolts.
8. NOTE: The service tools designed for a nominal pinion with 0 etch.
NOTE: Use a feeler gauge or clean, flat drive position shims as a measuring device.
NOTE: Do not attempt to force the feeler gauge or shims between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
Measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to the Pinion Ring Gear Variation Number for shim selection information.
9. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly as directed or unit failure can result.
Install the correct thickness drive pinion position shim, and the oil slinger, if so equipped, on the pinion.
10. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion position shim selection.
Using the special tools and a suitable press, install the inner pinion bearing.
11. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the chart.
Available Drive Pinion Bearing Preload Shims
12. Assemble the drive pinion preload shims onto the pinion and install the pinion into the differential housing.
13. NOTE: Do not install the pinion oil seal at this time.
Using the special tool, install the pinion flange.
14. Install the old washer and pinion locknut.
15. Using a Nm (inch-pound) torque wrench, rotate the pinion. The torque must read.
^ To increase the bearing preload, remove drive pinion bearing preload shims. To decrease the preload, add pinion bearing preload shims.
16. With the drive pinion bearings at the correct preload as determined in this procedure, remove and discard the pinion locknut and washer.
17. Using the special tool, remove the pinion flange.
18. Coat the pinion seal rubber lips with the specified fill lubricant.
19. Using a suitable driver, install the differential pinion oil seal.
20. Coat the inner splines of the pinion flange with lubricant.
21. Using the special tool, install the pinion flange.
22. CAUTION: Always use a new washer and locknut.
Install the new washer and locknut. Tighten to specification.
23. Install the differential case and ring gear.
24. Install the rear driveshaft.