INSTALLATION
1.
Install oil baffle in rear pinion cup bore.
2.
Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (2).
3.
Install front pinion bearing cup with Installer D-146 (1) and Handle C-4171 (2).
4.
Install pinion front bearing (1).
5.
Install pinion front bearing oil slinger (1).
6.
Apply a light coating of gear lubricant on pinion seal lip. Install seal with Installer 8681 (1) and Handle C-4171 (2).
7.
Install pinion depth shim (1) on pinion gear shaft (2).
8.
Install rear pinion bearing (4) on the pinion gear (3) with Installer C-4040 (2) and a press (1).
9.
Install collapsible spacer (1) on pinion gear (3).
10.
Install pinion gear in housing.
11.
Install pinion flange (1) with Installer 8112 (2) and Cup 8109.
12.
Install new nut on the pinion gear. Hold pinion flange (1) with Flange Wrench C-3281 (2) and tighten nut to 217 Nm (160 ft. lbs.).
13.
Set torque wrench to 271 Nm (200 ft. lbs.) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until Pinion Torque To Rotate (PTTR) specification is achieved.
14.
Measure Pinion Torque To Rotate (1) after each 6.8 Nm (5 ft. lbs.) increment with an inch pound torque wrench (2).
Pinion Torque To Rotate is:
-
Original Bearings: 1 - 2 Nm (10 - 20 in. lbs.)
-
New Bearings: 2 - 4.5 Nm (20 - 40 in. lbs.)
15.
Install ring gear with new ring gear (2) bolts (1) and alternately tighten to 136 Nm (100 ft. lbs.).
CAUTION:
Never reuse the ring gear bolts. Failure to follow these instruction may result in damage.
16.
Install Tru-Lok indicator switch (1) into differential housing (2).
17.
Install differential case into axle housing.
18.
Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shaft. This will verify differential bearing preload.
Total Torque To Rotate is: Pinion Torque To Rotate plus 0.79 - 1.24 Nm (7 - 11 in lbs.).
NOTE:
If TTTR is too high, decrease shim thickness equally from both sides of the differential and check TTTR again. If TTTR is too low, increase shim thickness equally to both sides
of the differential and check TTTR again.