REMOVAL

NOTE: / The ring and pinion gears are serviced as a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.
  1. Remove propeller shaft(Refer to 03 - Differential and Driveline/Propeller Shaft/SHAFT, Drive/Removal).
  1. Remove differential from the housing(Refer to 03 - Differential and Driveline/Rear Axle - 11 1/2 AA/CASE ASSEMBLY, Differential/Removal).
  1. Place differential case (3) in a vise with soft metal jaw protectors.
  1. Remove andDISCARDthe bolts (2) holding ring gear to differential case.
  1. Drive ring gear (1) from differential case with a rounded punch (1) inserted through the differential ring gear bolt holes (3). Alternate punch location to gradually remove the ring gear.
  1. Hold pinion flange (1) with Flange Wrench8979(2) and remove pinion flange nut.
  1. Remove pinion flange (1) from pinion with pinion Puller8992(2).
  1. Remove pinion gear (1) from housing with pinion Driver8977(2) and a hammer.

NOTE: / Thread the driver on the pinion shaft till it bottoms out.
  1. Remove pinion seal with a slide hammer or pry bar.
  1. Remove front pinion bearing andDISCARDbearing.

NOTE: / Do not reuse front pinion bearing/cup.
  1. Remove collapsible spacer from the pinion shaft.
  1. Remove rear pinion bearing (1) with Bearing Splitter1130(2) and a press.
  1. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims.
  1. Remove front pinion bearing cup from the housing with a punch and hammer, andDISCARDcup.

NOTE: / Do not reuse front pinion bearing/cup.
  1. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is going to be replaced.

INSTALLATION

  1. InstallNEWfront pinion bearing cup with Installer8960(1) and HandleC-4171(2).
  1. InstallNEWrear pinion bearing cup with InstallerInstaller, Bearing Cup 10062A(1) andC-4171(2).
  1. Install pinion depth shim (1) on the pinion gear shaft (2).
  1. Install rear pinion bearing (4) with InstallerInstaller, Rear Pinion Bearing 2019200030(2) and a press (1).
  1. InstallNEWcollapsible spacer (1) on the pinion (2).
  1. Lubricate pinion and bearings.
  1. Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer8981(1).
  1. InstallNEWpinion seal with Installer8896(2) and HandleC-4171(1).
  1. Apply a light coat of teflon sealant to the pinion flange splines.
  1. Hold pinion and lightly tap the pinion flange (2) onto the pinion, until a few threads are showing.
  1. Install pinion flange washer andNEWpinion nut.
  1. Hold pinion flange (2) with Flange Wrench8979(1) and tighten pinion nut until pinion end play is eliminated.
  1. Rotate pinion several times to seat pinion bearings.
  1. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 N·m (5 ft. lbs.) increments until pinion torque to rotate is achieved. Pinion Torque To Rotate is:
  2. New Pinion Bearings:1.7 - 2.8 N·m (15 - 25 in. lbs.)
  3. Original Pinion Bearings:1.1 - 2.2 N·m (10 - 20 in. lbs.)
  1. Rotate pinion several times then verify pinion rotating torque again.
  1. Position the ring gear (2) on differential case (4) and start twoNEWring gear bolts.
  1. Install the rest of theNEWring gear bolts and tighten them alternately to seat the ring gear.
  1. Torque ring gear bolts to 237 N·m (175 ft. lbs.).
  1. If exciter ring was removed, position differential assembly on differential Plug8965and place exciter ring (1) on the differential case.
  1. Install the exciter ring on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (2).
  1. Install differential in housing.
  1. Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench. Total Torque To Rotate is:
  2. New Bearings:3.4 - 5.6 N·m (30 - 50 in. lbs.)
  3. Original Bearings:2.8 - 5.1 N·m (25 - 45 in. lbs.)

NOTE: / If TTTR is to high, back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low, tighten adjusters evenly on both sides slightly and check TTTR again.
  1. Verify ring gear backlash and gear contact pattern.