Differential Ring and Pinion

Differential Ring And Pinion

Special Tool(s):

Material:

Removal
1. Remove the differential carrier.
2. Remove the 10 differential ring gear bolts and the differential ring gear.
^ Use a drift punch to separate the differential ring gear from the differential case.

3. Using the special tools, remove the 2 differential bearings.

4. Index-mark the pinion flange to the drive pinion gear.

5. Install the special tool and loosen, but do not remove, the pinion nut.
^ Remove the special tool.

6. With the pinion nut still engaged by a few threads, use the special tool to separate the pinion flange from the drive pinion gear.

7. Remove the pinion nut and the pinion flange.

8. CAUTION: Do not damage the axle housing while removing the drive pinion seal.

Remove the drive pinion seal and drive pinion oil slinger.
^ Pry up on the drive pinion seal flange. Install gripping pliers, and strike with a hammer to remove the drive pinion seal.

9. Remove the outer drive pinion bearing.
10. Using the special tool and a soft hammer, remove the drive pinion gear.

11. Remove and discard the drive pinion collapsible spacer.

12. Using the special tools, remove the inner drive pinion bearing cup.

13. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.

If necessary, remove the pinion bearing oil baffle.

14. Remove the outer drive pinion bearing cup by tapping alternately on each side to prevent the drive pinion bearing cup from becoming misaligned.

Installation

1. CAUTION: Do not omit the drive pinion bearing oil baffle; drive pinion bearing failure can result.

If removed, position the drive pinion bearing oil baffle on the special tool.

2. Using the special tool, install the drive pinion bearing oil baffle.

3. Using the special tool, install the drive pinion bearing cups.

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.

Assemble and position the special tools.

5. NOTE: This step duplicates final drive pinion bearing preload.

Tighten the special tool.
^ 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 and position the special tool.

7. Install the special tool.
1 Position the special tool.
2 Install the differential bearing caps.
3 Install the 4 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 final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
^ Notice the plus (+), minus (-) or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
^ After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.

9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.

10. NOTE: You must use the same drive pinion bearings from the previous steps.

Install the inner drive pinion bearing.
^ Place the drive pinion bearing adjustment shim on the drive pinion gear.
^ Using a suitable press and the special tool, press the inner drive pinion bearing until it is firmly seated on the pinion gear.

11. Place a new drive pinion collapsible spacer on the drive pinion gear.

12. Install the outer drive pinion bearing.

13. Install the drive pinion oil slinger.

14. NOTE: Coat the drive pinion seal lips with long-life grease.

Install the drive pinion seal on the special tool.

15. CAUTION: Installation without the correct tool can result in early drive pinion seal failure.

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

Using the special tool, install the drive pinion seal.

16. Lightly lubricate the drive pinion gear splines with axle lubricant.
17. Position the drive pinion gear in the axle housing.

18. CAUTION: Never install the pinion flange with a hammer or power tools.

Position the pinion flange.
^ Position the pinion flange on the drive pinion gear.

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

20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new pinion nut.

21. CAUTION: Do not loosen the pinion nut to reduce drive pinion bearing preload under any circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive pinion collapsible spacer and pinion nut.

Install the special tool and tighten the pinion nut.
^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench.

22. Press the left and right differential bearing on the differential carrier.
1 Position the differential bearing.
2 Using the special tool, press the differential bearing on the differential carrier.

23. 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 carrier 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.

24. Install the ring gear bolts after applying sealer to the bolt threads.
^ Use stud and bearing mount.
^ Tighten to 105 Nm (77 ft. lbs.).

25. Install the differential carrier.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential carrier in place.

26. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.

27. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.

Install the left bearing cap and loosely install the bearing cap bolts.

28. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.

29. Install the right bearing cap and bolts.
30. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

31. Rotate the differential carrier to make sure it turns freely.

32. Install the special tool at the 12 o'clock position.

33. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
1 Attach the special tool.
2 Position the special tool tip centrally on a drive tooth.
3 Zero the indicator.
4 Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 mm (0.008 inch) to 0.305 mm (0.012 inch) and must not vary more than 0.101 mm (0.004 inch) between points measured. A backlash variation of more than 0.101 mm (0.004 inch) between points checked indicates gear/case runout.
^ To correct for a high or low backlash, proceed as follows.

34. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash.

Differential Shim Size Chart - 4067 -:

35. Remove the 4 differential bearing cap bolts.
^ Remove the differential carrier.

36. Measure the thickness of the selected right and left bearing shims.
37. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 inch).
38. Install the special tools.

39. CAUTION: Overspreading may damage the differential housing.

NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.

Spread the differential housing to the specification.
1 Adjust the special tool to zero.
2 Tighten the screw until spreading the differential housing to the specification.
3 Remove the special tools.

40. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.

Place the differential bearing shims in the differential housing.

41. Install the differential carrier.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential carrier in place between the differential bearing shims.

42. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.

43. Loosen and remove the special tool.

44. Tighten the 4 differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

45. Rotate the differential carrier to make sure it turns freely.

46. Install the special tool at the 12 o'clock position.

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

48. Apply marking compound and rotate the differential assembly 5 complete revolutions.

49. Verify an acceptable pattern check.
50. Install a new retainer circlip on each axle shaft.

51. Insert the axle shafts and engage them with the differential side gears.

52. Push in on the axle shafts until the retaining circlips expand in the differential side gears.

53. Remove the axle assembly from the special tool and place it on the bench.

54. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.

CAUTION: Allow the sealant to cure for 1 hour before filling the axle with lubricant.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
^ Use silicone gasket and sealant.

55. Install the differential housing cover.
56. Fill the axle assembly with the specified amount any type of axle lubricant.
57. Install the rear axle assembly.