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Pinion Bearing: Service and Repair




Differential Drive Pinion Gear Bearing Replacement

Special Tools

* DT 49905 - Inner Pinion Bearing cup Remover

* DT 49906 - Inner Pinion Bearing Cup Remover

* J-7817 - Outer Pinion Bearing Race Installer

* J-8092 - Driver Handle 3/4 in-10

* J-21128 - Pinion Seal Installer

* J-22306 - Inner Pinion race Installer

* J-22912-B - Split Plate Bearing Puller

* J-24433 - Inner Pinion Bearing Installer

* J 29609 - Rear Pinion Bearing Cup Installer

* J-37758 - Outer Pinion Race Installer

* J-38694 - Pinion Seal Installer

* J-39441 - Inner Pinion Bearing Installer

* J-42176 - Driver Handle (non-Threaded)

* J-45012 - Holding Fixture

* J-45019 - Flange and Pinion Cage Remover

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Disassemble Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the differential pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (195/218 mm Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (195/218 mm Axle)Drive Pinion Flange/Yoke and/or Oil Seal Replacement (250mm Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (250 mm Axle).

3. Remove the differential assembly. Refer to Differential Replacement (195/218mm) Differential Replacement (195/218 mm)Differential Replacement (250mm) Differential Replacement (250 mm).





Note:
Position a block of wood under the differential housing to protect the pinion gear when removed.

4. Using a hydraulic press and a block of wood (1), remove the pinion gear (2).

Note:
Use the slot on each side of the pinion bearing to position the brass drift to remove the bearing cup. Also, alternate from side to side when removing the bearing.

5. Using a hammer and a brass drift, remove the outer pinon bearing cup from the differential housing.





6. Using the following special tools to remove the inner pinion bearing cup.

* For the 195 mm axle, use the DT 49905 - Inner Pinion Bearing cup Remover (2) and the J-42176 - handle (1).

* For the 218 mm axle, use the DT 49906 - Inner Pinion Bearing cup Remover (2) and the J-42176 - handle (1).

Assemble Procedure





1. Using the following special tools, install the outer pinion bearing cup.

* For the 195 mm axle, use the and the J-7817 - installer (2) and the J-8092 - handle (1).

* For the 218 mm axle, use the J-37758 - installer (2) and the J-8092 - handle

(1).





2. Using the following special tools, install the inner pinion bearing cup.

* For the 195 mm axle, use the J 29609 - installer (2) and the J-8092 - handle (1).

* For the 218 mm axle, use the J-22306 - installer (2) and the J-8092 - handle (1).

3. Determine the selective shim thickness for the pinion bearing. Refer to Pinion Depth Adjustment (195/218mm) Pinion Depth Adjustment (195/218 mm)Pinion Depth Adjustment (250mm) Pinion Depth Adjustment (250 mm)

4. Install the selective shim between the inner pinion bearing and the shoulder on the gear.





Note:
Ensure the bearing is fully seated on the pinion gear.

5. Using the following special tool to install the inner pinion bearing.

* For the 195 mm axle, use the J-39441 - installer

* For the 218 mm axle, use the J-24433 - installer

6. Install the NEW collapsible spacer.

7. Use the proper axle lubricant on the pinion bearings, refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications.





8. Using the following special tool to install the NEW pinion seal (2).

* For the 195 mm axle, use the J-21128 - installer (1).

* For the 218 mm axle, use the J-38694 - installer (1).

9. Using a soft face hammer, to seat the pinion yoke onto the pinion shaft until a few pinion shaft threads show through the yoke.

10. Install the washer and a new pinion nut.

11. Using the J-45012 - fixture, tighten the pinion nut until the pinion end play is just taken up.

Note:
If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

12. Using an inch pound torque wrench, measure the rotating torque.

* For the 195 mm axle, the torque should be 2.0-2.6 Nm (18-23 lb in) for NEW bearings or 1.0-2.3 Nm(9-20 lb in) for used bearings.

* For the 218 mm axle, the torque should be 2.1-3.1 Nm (19-27 lb in) for NEW bearings or 1.0-2.3 Nm(9-20 lb in) for used bearings.

13. If the rotating torque measurement is below the minimum torque value, continue to tighten the pinion nut in small increments until the torque is within the specifications.

14. Install the differential assembly. Refer to Differential Replacement (195/218mm) Differential Replacement (195/218 mm)Differential Replacement (250mm) Differential Replacement (250 mm).

15. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement Removal and Replacement.

16. Lower the vehicle.

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