Ring and Pinion Explanation

RING AND PINION GEAR REMOVAL
NOTE: The ring and pinion gears are serviced as a matched set. Never replace one gear without replacing the other gear.
1. Remove differential assembly from axle housing.
2. Remove ring gear bolts (Fig 1) #1 and remove ring gear #2 from differential case.
3. Remove Tru-Lok indicator switch (Fig 2) #1 from differential housing #2.
4. Hold pinion flange (Fig 3) #1 with Flange Wrench (special tool #C-3281, Holder, Flange) #2 and remove pinion nut.
5. Remove pinion flange (Fig 4) #1 with Puller (special tool #C-452, Puller, Companion Flange) #2.
6. Remove pinion gear from housing with dead blow hammer (Fig 5) #1.
7. Remove collapsible spacer (Fig 6) #1 from pinion gear #3.
8. Remove rear pinion bearing from pinion shaft (Fig 7) #1 with Puller (special tool #C-293-PA, Puller, Press) #2 and Adapters (special tool #C-293-47, Block Set, Puller) #3.
9. Remove pinion depth shim (Fig 8) #1 from pinion shaft #2 and record thickness.
10. Remove pinion seal with seal puller.
11. Remove front bearing oil slinger (Fig 9) #1.
12. Remove front pinion bearing (Fig 10) #1.
13. Remove front pinion bearing cup with Remover (special tool #D-158, Remover, Bearing Cup) (Fig 11) #1 and Handle (special tool #C-4171, Driver Handle, Universal) #2.
14. Remove rear bearing cup (Fig 12) #1 and oil baffle with a hammer and punch #2.

RING AND PINION GEAR INSTALLATION
1. Install oil baffle in rear pinion cup bore.
2. Install rear pinion bearing cup with Installer (special tool #C-4308, Installer, Bearing Cup) (Fig 13) #1 and Handle (special tool #C-4171, Driver Handle, Universal) #2.
3. Install front pinion bearing cup with Installer (special tool #D-146, Installer, Bearing Cup) (Fig 14) #1 and Handle (special tool #C-4171, Driver Handle, Universal) #2.
4. Install pinion front bearing (Fig 10) #1.
5. Install pinion front bearing oil slinger (Fig 9) #1.
6. Apply a light coating of gear lubricant on pinion seal lip. Install seal with Installer (special tool #8681, Installer, Seal) (Fig 15) #1 and Handle (special tool #C-4171, Driver Handle, Universal) #2.
7. Install pinion depth shim (Fig 8) #1 on pinion gear shaft #2.
8. Install rear pinion bearing (Fig 16) #4 on the pinion gear #3 with Installer (special tool #C-4040, Installer, Bearing) #2 and a press #1.
9. Install a NEW collapsible spacer (Fig 6) #1 on pinion gear #3.
10. Install pinion gear in housing.
11. Install pinion flange (Fig 17) #1 with Installer (special tool #8112, Screw) #2 and Cup (special tool #8109, Cup).
12. Install NEW nut on the pinion gear. Hold pinion flange (Fig 3) #1 with Flange Wrench (special too l#C-3281, Holder, Flange) #2 and tighten nut to 217 N.m (160 ft. lbs.).
13. Set torque wrench to 271 N.m (200 ft. lbs.) and tighten pinion nut in 6.8 N.m (5 ft. lbs.)
increments until Pinion Torque to Rotate (PTTR) specification is achieved.
14. Measure Pinion Torque to Rotate (Fig 16) #1 after each 6.8 N.m (5 ft. lbs.) increment with an inch pound torque wrench #2.

Pinion Torque To Rotate is:
1. Original Bearings: 1 - 2 N.m (10 - 20 in. lbs.)
2. New Bearings: 2 - 4.5 N.m (20 - 40 in. lbs.)

15. Install ring gear with NEW ring gear (Fig 1) #2 bolts #1 and alternately tighten to the proper Torque Specifications. Refer to SPECIFICATIONS

CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction may result in damage.
16. Install Tru-Lok indicator switch (Fig 2) #1 into differential housing.
17. Install differential case into axle housing. Refer to CASE ASSEMBLY, DIFFERENTIAL, TRU-LOK, INSTALLATION
18. Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (Fig 18) #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 N.m (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.