Installation

INSTALLATION




1. Install left hand thread ring gear Installer Bolts 9533 (1) through differential (2) and into ring gear. Tighten nuts on installer bolts evenly and draw ring gear onto differential case.
2. Remove installer bolts and install new ring gear bolts and tighten to 122 Nm (90 ft. lbs.).




3. Install front pinion bearing cup into housing, with Installer D-129 (1) and Handle C-4171 (2).




4. Install pinion depth shim (1) in rear pinion bearing cup bore (2).




5. Install rear pinion bearing cup into housing, with Installer D-111 (1) and Handle C-4171 (2).





WARNING: Use welding gloves when handling heated components.

CAUTION: A bearing heater is used to assembly some components. Use only an approved heater and only heat components to 100 - 149� Celsius (212 - 300� Fahrenheit). Never leave components on heater for and extended amount of time. If component is discolored after heating, component has been overheated and must not be used. Failure to follow these instructions will result in damage.

6. Heat rear pinion bearing (1) with bearing heater (2).
7. Using welding gloves or tongs, install rear bearing on pinion shaft.




8. Install spacer (1) on pinion shaft (2) with the beveled side facing the gear.




9. Install new collapsible spacer (1) on pinion shaft (2).




10. Install pinion in housing.
11. Install front pinion bearing into the housing (1) on the pinion shaft with Installer 9616 (2). Thread installer onto the pinion shaft then tighten installer nut.




12. Install pinion seal with Installer C-3972A.
13. Install pinion flange (1) on pinion with Installer 9616 (2). Tap flange on pinion, then thread installer center bolt on pinion shaft and draw flange onto the pinion.




14. Hold pinion flange (1) with Flange Wrench C-3281 (2) and tighten new pinion nut until pinion torque to rotate is 1.5 - 1.9 Nm (13 - 17 in. lbs.).




15. Cut the pinion nut collar.
16. Bend nut collar so it touches the wall of the slot in the pinion shaft.
17. Install differential.