Differential & Driveline

DRIVELINE VIBRATION

Drive Condition	Possible Cause	Correction
Propeller Shaft Noise	1. Undercoating or other foreign	1. Clean exterior of shaft and wash
material on shaft.	with solvent.
2. Loose propeller shaft.	2. Install new screws and tighten

to proper torque. 3. Loose or bent joint or excessive 3. Install new propeller shaft. runout. 4. Incorrect driveline angularity. 4. Measure and correct driveline angles. 5. Worn joint. 5. Install new propeller shaft 6. Propeller shaft damaged or out 6. Install new propeller shaft. of balance. 7. Broken rear spring. 7. Install new rear spring. 8. Excessive runout or unbalanced 8. Re-index propeller shaft, test,

                                     condition.                          and evaluate.
                                     9. Excessive drive pinion gear      9. Re-index propeller shaft and
                                     shaft runout.                       evaluate.
                                     10. Excessive pinion flange         10. Inspect and replace propeller
                                     deflection.                         shaft if necessary.

11. Excessive transfer case runout. 11. Inspect and repair as necessary. Joint Noise 1. Loose screws. 1. Install new screws and tighten to proper torque. 2. Lack of lubrication. 2. Replace propeller shaft as necessary.

A out of round tire or wheel that is out of balance, will cause a low frequency vibration.

Brake rotors that are unbalanced will cause a harsh, low frequency vibration.

Driveline vibration can be caused by loose or damaged engine mounts.

Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed is not usually

caused by a out of balance propeller shaft. Worn universal joints or an incorrect propeller shaft angle, can cause such a vibration.

BALANCE📷 3

NOTE: Indexing the propeller shaft (1) 90° relative to the flange (2) may eliminate some vibrations.

1. Raise the vehicle. 2. Clean all the foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds, and bent areas.

NOTE: If the propeller shaft is bent, it must be replaced.

4. Inspect joints for wear, proper installation and correct alignment with the shaft. 5. Remove wheels and tires and install wheel lug nuts to retain brake drums/rotors. 6. Mark and number the shaft six inches from the pinion flange end at four positions 90 degrees apart. 7. Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 8. Position one screw clamp (1) on the propeller shaft (2) at one of the 90 degree marks. 9. Start the engine and check for vibration. If there is little or no change in vibration, move the clamp to the next mark. Repeat the vibration test. If there is no difference in vibration at the other positions, the source of the vibration may not be propeller shaft.

10. If vibration is decreased, install a second clamp (1) in the same position on the propeller shaft (2) and repeat the test.

11. If the additional clamp causes an additional vibration, separate the clamps (1) 1/4 inch above and below the mark. Repeat the vibration test. 12. Increase distance between the clamps and repeat the test until the amount of vibration is at the lowest level. Bend the slack end of the clamps so the screws will not loosen. 13. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 14. Install wheel and tires, and lower vehicle.

RULES📷 1

Good cancellation of U-joint operating angles is within 1 degree.

Operating angles less than 4 degrees single cardan U-joint.

Operating angles less than 10 degrees for CV joints.

NOISE/VIBRATION IN TURNS

A clicking noise or vibration in turns could be caused by a damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss/contamination of the joint grease, resulting in inadequate lubrication of the joint. Noise could also be caused by another component of the vehicle coming in contact with the half shafts.

CLUNKING NOISE DURING ACCELERATION

This noise may be a damaged or worn C/V joint. A torn boot or loose/missing clamp on the inner/outer joint which has allowed the grease to be lost will damage the C/V joint.

SHUDDER/VIBRATION DURING ACCELERATION

This could be a worn/damaged inner tripod joint or a sticking tripod joint. Improper wheel alignment may also cause a shudder or vibration.

VIBRATION AT HIGHWAY SPEEDS

This problem could be a result of out of balance front tires or tire/wheel runout. Foreign material (mud, etc.) packed on the backside of the wheel(s) will also cause a vibration.

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears or the carrier housing not having the proper offset and squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly check for:

Insufficient lubricant Incorrect ring gear backlash Gear damage

Differential side and pinions gears, usually do not cause noise during straight-ahead driving, when the gears are unloaded. The side gears are loaded during turns. A worn pinion mate shaft can also cause a snapping or a knocking noise.

BEARING NOISE

Bearing noise can be either a whining or a growling sound.

Pinion bearings have a constant high pitch noise, because it rotates at a faster rate. This noise changes with vehicle speed. If noise is heard under a load, the rear pinion bearing is the source. If noise is heard during a coast, the front pinion bearing is the source.

Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and varies only with vehicle speed.

Axle shaft bearing noise generally changes when the bearings are loaded. Turn vehicle sharply to the left and the right during a road test. This will load and unload the bearings and change the noise level. If axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 m.p.h.

LOW SPEED KNOCK

Low speed knock is generally caused by:

Worn U-joints/CV joint Worn side-gear thrust washers Worn pinion shaft bore

VIBRATION

Vibration at the rear of the vehicle is usually caused by:

Damaged drive shaft Missing drive shaft balance weight(s) Worn or out-of-balance wheels Loose wheel lug nuts Worn U-joints/CV joint Loose/broken springs Damaged axle shaft bearing(s) Loose pinion gear nut Excessive pinion yoke run out Bent axle shaft(s)

Check for loose or damaged front-end components or engine/transmission mounts. These components can contribute to what appears to be an axle vibration. Also look at engine accessories, brackets and drive belts.

NOTE: All driveline components should be examined before starting any repair.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged, can be caused by:

High engine idle speed Transmission shift operation Loose engine/transmission/transfer case mounts Worn U-joints/CV joint Loose spring mounts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive side gear to case clearance

To determined the source of a snap/clunk noise, raise vehicle on a hoist with the wheels free to rotate. Have a helper shift the transmission into gear and listen for the noise.

DIAGNOSTIC CHART

Condition	Possible Causes	Correction
Wheel Noise	1. Wheel loose.	1. Tighten loose nuts.
2. Worn wheel bearing.	2. Replace bearing.
Axle Noise	1. Misaligned axle tube.	1. Inspect axle tube alignment.

Correct as necessary. 2. Bent or sprung axle shaft. 2. Inspect and correct as necessary. 3. End-play in pinion bearings. 3. Refer to pinion pre-load information and correct as

necessary. 4. Excessive gear backlash 4. Check adjustment of the ring between the ring gear and pinion. gear and pinion backlash. Correct as necessary. 5. Improper adjustment of pinion 5. Adjust the pinion bearings pre-

                            gear bearings.                    load.
                            6. Loose pinion yoke nut.         6. Tighten the pinion yoke nut.
                            7. Scuffed gear tooth contact     7. Inspect and replace as
                            surfaces.                         necessary.
Axle Shaft Broke            1. Misaligned axle tube.          1. Replace the broken shaft after

correcting tube mis-alignment. 2. Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch. 4. Replace broken shaft and inspect and repair clutch as necessary.

Differential Cracked        1. Improper adjustment of the     1. Replace case and inspect gears
                            differential bearings.            and bearings for further damage.

Set differential bearing pre-load properly. 2. Excessive ring gear backlash. 2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly. 3. Vehicle overloaded. 3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight. 4. Erratic clutch operation. 4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch. Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with the correct fluid type and quantity.

                            3. Excessive spinning of one      3. Replace scored gears. Inspect
                            wheel/tire.                       all gears, pinion bores, and shaft

for damage. Service as necessary. Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level. 2. Worn axle shaft seals. 2. Replace seals. 3. Cracked differential housing. 3. Repair as necessary.

                            4. Worn pinion seal.              4. Replace seal.
                            5. Worn/scored yoke.              5. Replace yoke and seal.

6. Axle cover not properly sealed. 6. Remove, clean and seal cover.

Axle Overheating      1. Lubricant level low.             1. Fill differential to correct level.
                      2. Improper grade of lubricant.     2. Fill differential with the correct

fluid type and quantity. 3. Bearing pre-loads too high. 3. Adjust bearing pre-loads. 4. Insufficient ring gear backlash. 4. Adjust ring gear backlash. Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation. 3. Ice-spotted pavement. 3. Replace gears and examine remaining parts for damage. 4. Improper adjustments. 4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct. Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2. Check ring gear and pinion

                      adjustment.                         contact pattern.
                      3. Unmatched ring gear and          3. Replace gears with a matched
                      pinion.                             ring gear and pinion.
                      4. Worn teeth on ring gear or       4. Replace ring gear and pinion.

pinion.

                      5. Loose pinion bearings.           5. Adjust pinion bearing pre-load.
                      6. Loose differential bearings.     6. Adjust differential bearing pre-

load. 7. Ring gear run-out. 7. Measure ring gear run-out. Replace components as necessary. 8. Loose differential bearing cap 8. Inspect differential components bolts. and replace as necessary. Ensure that the bearing caps are torqued to specifications. 9. Housing not machined properly. 9. Replace housing.

PINION GEAR DEPTH VARIANCE

Original Pinion Gear	Replacement Pinion Gear Depth Variance
Depth Variance	-4	-3	-2	-1	0	+1	+2	+3	+4
+4	+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001	0
+3	+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001	0	-0.001
+2	+0.006 +0.005 +0.004 +0.003 +0.002 +0.001	0	-0.001	-0.002
+1	+0.005 +0.004 +0.003 +0.002 +0.001	0	-0.001 -0.002	-0.003
0	+0.004 +0.003 +0.002 +0.001	0	-0.001 -0.002 -0.003	-0.004
-1	+0.003 +0.002 +0.001	0	-0.001 -0.002 -0.003 -0.004	-0.005
-2	+0.002 +0.001	0	-0.001 -0.002 -0.003 -0.004 -0.005	-0.006
-3	+0.001	0	-0.001 -0.002 -0.003 -0.004 -0.005 -0.006	-0.007
-4	0	-0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007	-0.008

PINION DEPTH MEASUREMENT📷 3

Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indicator C-3339A (1).

1. Assemble Pinion Height Block 6739 (3), Pinion Block 8804 (6) and rear pinion bearing onto Screw 6741 (5). 2. Insert height gauge components into the housing through pinion bearing cups. 3. Install front pinion bearing and Cone-nut 6740 (4) onto the screw. Tighten Cone-Nut until Torque To Rotate screw is 1.7 N.m (15 in. lbs.).

4. Position Arbor Discs 6927A (1) and Arbor D-115-3 (2) into the housing bearing cradles.

5. Install differential bearing caps (1) on Arbor Discs and tighten bolts (2) to 61 N.m (45 ft. lbs.).

6. Assemble Dial Indicator C-3339A into Scooter Block D-115-2 and secure set screw. 7. Position Dial Indicator (1) with Scooter Block (2) flush on the pinion height block. Hold scooter block and zero the dial indicator. 8. Slowly slide the scooter block (2) across the pinion block over to the arbor (3). Move the scooter block till the dial indicator probe crests the arbor (3) and record the highest reading. 9. Select a shim equal to the dial indicator reading plus or minus the pinion depth variance number on the face of the pinion. For example: If the depth variance is -2, add 0.002 in. to the dial indicator reading. If the depth variance is +2, subtract 0.002 in. from the dial indicator reading.

DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH📷 1

Differential bearing preload and gear backlash is achieved with selective shims (2) (4) located between the differential bearing cups and differential housing. Shim thickness is determined using Dummy Bearings D-348 and Dummy Shims 8107 in place of the differential side bearings and preload shims.

Before measuring differential bearing preload and gear backlash, pinion gear depth must be established and pinion gear prepared for installation. Pinion gear depth is essential to establishing gear backlash and tooth contact patterns.

PRELOAD SHIM SELECTION📷 11

1.   Remove differential side bearings from differential case.
  2.   Install ring gear on differential case and tighten bolts to specification.
  3.   Install Dummy Bearings D-348 (1) on differential case.
  4.   Install differential case in the housing.
  5.   Record thickness of Dummy Shims 8107 (2) then install shims between dummy bearings and differential

housing.

NOTE: Each dummy shim is 3 mm (0.118 in.) thick.

6. Install bearing caps (1) in their correct positions and snug bearing cap bolts (3).

7. With a dead-blow hammer (1), seat differential dummy bearing to pinion side of the housing (2).

8. With a dead-blow hammer (2), seat differential dummy bearing to ring gear (3) side of the housing (1).

9. Thread Pilot Stud C-3288-B (2) into rear cover bolt hole below ring gear. 10. Attach a Dial Indicator C-3339A (3) to the Pilot Stud. Position the dial indicator plunger on flat surface between the ring gear bolts. 11. Push and hold differential case to pinion gear side (1) of the housing and zero dial indicator.

12. Push and hold differential case to ring gear side of the housing (2) and record dial indicator (1) reading. 13. Add dummy shims thickness 6 mm (0.236 in.) plus preload specification 0.152 mm (0.006 in.) to the dial indicator reading. This is the total shim thickness needed to preload the new bearings when the differential is installed.

EXAMPLE: Differential Dial Indicator Reading + Dummy Shims 6 mm (0.236 in.) + Preload Specification 0.152 mm (0.006 in.) = Total Differential Shim

14. Rotate dial indicator out of the way on the pilot stud. 15. Remove differential case and dummy bearings from the housing.

16. Install pinion gear in the housing. Install the pinion flange (1) and establish pinion torque to rotate with an inch pound torque wrench (2).

17. Install differential case and Dummy Bearings D-348 in the housing. 18. Install a single dummy shim in the ring gear side. Install bearing caps (1) and tighten bearing cap bolts (3) snug.

19. Seat ring gear side dummy bearing. 20. Position the dial indicator (1) plunger on a flat surface between the ring gear (3) bolt heads. 21. Push and hold differential case toward pinion gear (2) and zero dial indicator (1).

22. Push and hold differential case (2) to ring gear side (3) of the housing and record ring gear side dial indicator (1) reading. Add 3 mm (0.118 in.) one dummy shim thickness to ring gear side reading. 23. Subtract backlash specification 0.076 mm (0.003 in.) from total ring gear side reading for ring gear backlash. This is the shim needed on the ring gear side of the differential.

EXAMPLE: Ring Gear Side Dial Indicator Reading + One Dummy Shim 3 mm (0.118 in.) - Backlash Specification 0.076 mm (0.003 in.) = Ring Gear Side Shim

24. Subtract ring gear shim total from preload shim total thickness. The remainder is the shim thickness needed on the pinion side of the differential.

EXAMPLE : Total Differential Shim - Ring Gear Side Shim = Pinion Gear Side Shim

25. Rotate dial indicator out of the way on pilot stud. 26. Remove differential case and dummy bearings from the housing. 27. Install side bearings and cups on differential case.

28. Install Spreader Adapters 9959, Spreader W-129-B (1) and Spreader Retainers W-129-1 (2) on housing tighten spreader turnbuckle finger-tight. 29. Attach Dial Indicator C-3339 to spreader retainer stud. Load indicator plunger against opposite side of the housing and zero the indicator 30. Spread the differential case 0.34 mm (0.013 in).

CAUTION: Never spread the differential housing over 0.34 mm (0.013 in). Failure to follow these instruction could result in distorting the housing.

31. Install differential case with shims.

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GEAR BACKLASH📷 3

1.   Rotate the differential case several times to seat the side bearings.
  2.   Position the indicator plunger (1) against a ring gear tooth (2).
  3.   Push and hold ring gear upward while not allowing the pinion gear to rotate.
  4.   Zero dial indicator face to pointer.
  5.   Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading

(backlash ) should be between 0.12 - 0.20 mm (0.005 - 0.008 in.).

NOTE: If backlash is not within specifications, transfer the necessary shim thickness from one side of the housing to the other.

6. Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.

After the proper backlash is achieved, perform Gear Contact Pattern Analysis procedure.

GEAR CONTACT PATTERN📷 1

The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.

The TOP LAND (1) of the gear tooth is the top surface of the tooth. The PROFILE (2) of the gear tooth is the depth of the tooth. The TOE (3) of the gear is the portion of the tooth surface at the end towards the center. The HEEL (4) of the gear is the portion of the tooth at the outer-end. The ROOT (5) of the gear tooth is the lowest portion of the tooth.

NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered, it is a 2 Axis cut gear.

1. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth. 2. Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion.

This will provide a more distinct contact pattern. 3. With a boxed end wrench on a ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.

The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash as necessary.

DIFFERENTIAL BEARING PRELOAD CHECK📷 2

With an inch pound torque wrench (2) measure Total Torque To Rotate (TTTR). This is the final check on the differential assembly before installing the axle shafts. This will verify the correct differential bearing preload.

Total Torque to Rotate is, Pinion Torque To Rotate (PTTR) plus:

Gear Ratio 3.21: 0.34 - 1.24 N.m (3 - 10.9 in. lbs.) Gear Ratio 3.73: 0.45 - 0.75 N.m (3.9 - 6.6 in. lbs.)

NOTE: If TTTR is high, decrease the shim thickness equally on both sides of the differential and check TTTR again. If TTTR is low, increase the shims thickness equally on both sides of the differential and check TTTR again.

DESCRIPTION SPECIFICATION📷 30

Axle Ratio                      3.21/3.73
   Ring Gear Diameter             186 mm (7.33 in.)
    Ring Gear Runout             0.12 mm (0.005 in.)

0.12 - 0.20 mm (0.005 - Ring Gear Backlash 0.008 in.) Pinion Torque To Rotate: 1 - 2.2 N.m (10 - 20 in. lbs.) Original Bearings

  Pinion Torque To Rotate:     1.7 - 2.8 N.m (15 - 25 in.
       New Bearings                       lbs.)

Total Torque To Rotate is Pinion Torque To Rotate plus: - 0.53 - 0.87 N.m (4.6 - 7.7 in. Gear Ratio 3.21 lbs.) 0.45 - 0.75 N.m (3.9 - 6.6 in. Gear Ratio 3.73 lbs.)

Torque

DESCRIPTION	N.m	Ft. Lbs.	In. Lbs.
Ring Gear Bolts	108	80	-

Differential Bearing Cap 54 - 68 39 - 50 - Bolts

Drain Trough Nut	23	-	200
Differential Cover Bolts	19 - 26	14 - 19	-
Pinion Nut	217 - 352	160 - 260	-
Rear Axle Bracket Bolts	88	65	-

Front Axle Brackets To 61 45 - Frame Nut Front Axle Bracket to 61 45 - Axle Nuts Right Axle Bracket Nut 61 45 -

Special tools

COVER-DIFFERENTIAL

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BUSHING-AXLE📷 1

CAUTION: Bushing must be installed in the original location ± 2 degrees. Failure to follow these instruction will result in a NVH problem.

PINION NOSE BUSHING📷 1

1. Mark bushing flange flat location (1) on the axle for installation reference.

2. Remove pinion nose bushing (1) with Remover 9958-5 (2) and Handle C-4171 (3). Drive bushing out with a hammer.

AXLE TUBE BUSHING📷 2

1. Mark bushing flange flat location (1) on the axle for installation reference.

2. Bolt (1) Remover 9958-3 (2) to axle tube bushing. Drive bushing out with a hammer.

AXLE BRACKET BUSHING📷 2

1. Mark bushing flange flat location (1) on the axle bracket for installation reference.

2. Clamp Press C-4212F into vise. 3. Place Spacer 9958-1 (1) over bushing in the bracket. Press bushing out of the bracket into Receiver 9958- 6 (1) with Remover 9958-5 (3) and Press C-4212F.

BUSHING-AXLE📷 1

CAUTION: Bushing must be installed in the original location ± 2 degrees. Failure to follow these instruction will result in damaging the bushing and a NVH problem.

PINION NOSE BUSHING📷 1

1. Start bushing in axle housing with bushing reference mark aligned. 2. Center one of the Receiver 9958-2 (1) flat spots (2) under pinion for tool clearance.

3. Install bushing (1) with Installer 9958-3 (2) Receiver 9958-2 (3) and Press C-4212F.

AXLE TUBE BUSHING📷 2

1. Start bushing in axle tube with bushing reference mark aligned. 2. Center one of the Receiver 9958-2 (3) flat spots over the axle tube for tool clearance. 3. Install bushing (1) with Installer 9958-3 (2) Receiver 9958-2 (3) and Press C4212F.

AXLE BRACKET BUSHING📷 2

1. Start bushing in axle bracket with bushing reference mark aligned. 2. Install bushing (1) with Receiver 9958-6 (2) Spacer 9958-1 (3) position in bracket, Installer 9958-3 (4) and Press C4212F. Press bushing through the first side of the bracket then remove Spacer 9958-1 (3). Verify bushing is aligned with the second side of the bracket. Installer Spacer 9958-1 (3) and press

bushing through the second side of the bracket.

SHAFT-AXLE

SEAL-PINION📷 3

1.   Remove brake calipers and rotors.
2.   Remove propeller shaft.
3.   Rotate pinion gear several times and verify the pinion rotates smoothly.
4.   Record pinion torque to rotate (1) with an inch pound torque wrench (2).

5. Hold pinion flange (1) with Flange Holder C-3281 (2) and remove pinion nut. 6. Mark a line on the pinion shaft and flange for installation reference.

7. Remove pinion flange with Puller C-452 (1) and Flange Holder C-3281 (2). 8. Remove pinion seal with a seal puller.

SEAL-PINION📷 4

1. Apply a light coating of gear lubricant on the lip of pinion seal. Install with Installer 8681 (1) and Handle C-4171 (2).

2. Position flange on the pinion shaft with the reference marks aligned. 3. Install flange with Installer W-162-D (1) and Screw 8112 (2).

4. Install a new nut on the pinion gear. Hold pinion flange (1) with Flange Holder C-3281 (2) and tighten pinion nut to 217 N.m (160 ft. lbs.).

NOTE: Do not exceed minimum tightening torque 217 N.m (160 ft. lbs.) at this

point.

5. Rotate pinion several times and verify pinion rotates smoothly. 6. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotating should be equal to recorded reading plus 0.56 N.m (5 in. lbs.).

If rotating torque is low, tighten the pinion nut in 6.8 N.m (5 ft. lbs.) increments until proper rotating torque is achieved.

CAUTION: If maximum tightening torque is reached 352 N.m (260 ft. lbs.) prior to reaching required rotating torque, the collapsible spacer may have been damaged. Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.

7. Install brake rotors, calipers and propeller shaft. 8. Fill differential with gear lubricant.

DIFFERENTIAL

GEAR-PINION/RING📷 8

NOTE: The ring gear and pinion are serviced as a matched set. Never replace ring gear without replacing the matched pinion gear.

1. Remove differential from axle housing. 2. Place differential case in a vise with soft jaws. 3. Remove ring gear bolts (1) and tap ring gear (2) off differential case with a dead-blow hammer.

4. Hold pinion flange (1) with Flange Holder C-3281 (2) and remove pinion nut.

5. Remove pinion flange with Puller C-452 (1) and Flange Holder C-3281 (2). 6. Remove pinion gear from housing with dead-blow hammer.

7. Remove pinion seal with seal puller. 8. Remove oil slinger (1) from housing (2).

9. Remove front pinion bearing (1) from housing (2).

10. Remove rear pinion bearing cup with a hammer and drift. 11. Remove front pinion bearing cup with Remover D-149 (1) and Handle C-4171 (2).

12. Remove collapsible spacer (1) from pinion shaft (2).

13. Remove rear pinion bearing from the pinion (1) with Puller C-293-PA (2) and Adapters C-293-42 (3).

14. Remove pinion depth shim (1) from the pinion shaft (2) and record thickness.

GEAR-PINION/RING📷 14

NOTE: Pinion depth shims are located under the rear pinion bearing. Refer to PINION DEPTH MEASUREMENT to select the proper thickness shim before installing

pinion gear. If ring and pinion gears are reused, the pinion depth shim should not require replacement.

1. Install front bearing cup with Installer D-146 (1) and Handle C-4171 (2).

2. Install rear bearing cup with Installer C-4308 (2) and Handle C-4171 (1).

3. Install pinion depth shim (1) on pinion shaft (2).

4. Install rear pinion bearing (4) on pinion (3) with Installer C-4040 (2) and a press (1).

5. Install a new collapsible spacer (1) on pinion shaft (2). 6. Install pinion in housing.

7. Install front pinion bearing (1) on pinion shaft (2).

8. Install front pinion bearing oil slinger (1) on pinion shaft (2).

9. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer 8681 (1) and Handle C-4171 (2).

10. Install pinion flange with Installer W-162-D (1) Screw 8112 (2).

11. Install new pinion nut. Hold flange (1) with Holder C-3281 (2) and tighten the nut to 217 N.m (160 ft. lbs.). Do not exceed minimum tighten torque 217 N.m (160 ft. lbs.). 12. With a torque wrench set at 352 N.m (260 ft. lbs.) tighten pinion nut until pinion end play is eliminated.

13. Rotate pinion several times to seat bearings and verify pinion (1) rotates smoothly. 14. Slowly tighten the pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotate is achieved. Measure rotating torque frequently to avoid over crushing the collapsible spacer.

15. Measure pinion torque to rotate (PTTR) with an inch pound torque wrench (2).

Pinion Torque To Rotate is:

Original Bearings: 1.0 - 2.2 N.m (10 - 20 in. lbs.). New Bearings: 1.7 - 2.8 N.m (15 - 25 in. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.

16. Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole

alignment. 17. Invert differential case in the vise. Install new ring gear (2) bolts (1) and alternately tighten to 108 N.m (80 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.

18. Install differential in housing.

19. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench (2). This will verify the correct differential bearing preload.

Total Torque to Rotate (TTTR) is Pinion Torque To Rotate (PTTR) plus:

Gear Ratio 3.21: 0.53 - 0.87 N.m (4.6 - 7.7 in. lbs.) Gear Ratio 3.73: 0.45 - 0.75 N.m (3.9 - 6.6 in. lbs.)

If TTTR is high, decrease shim thickness equally on both sides of the differential and check TTTR again. If TTTR is low, increase shim thickness equally on both sides of the differential and check TTTR again.

20. Verify differential gear contact pattern.

REAR AXLE - 8 1/4

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GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

Insufficient lubricant. Incorrect ring gear backlash. Gear damage.

BEARING NOISE

Bearing noise can be either a whining or a growling sound.

Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and varies only with vehicle speed.

LOW SPEED KNOCK

Low speed knock is generally caused by:

Worn U-joints/CV joint. Worn side-gear thrust washers. Worn pinion shaft bore.

VIBRATION

Vibration at the rear of the vehicle is usually caused by:

Damaged drive shaft. Missing drive shaft balance weight(s). Worn or out-of-balance wheels. Loose wheel lug nuts. Worn U-joints/CV joint. Loose/broken springs. Damaged axle shaft bearing(s). Loose pinion gear nut. Excessive pinion yoke run out. Bent axle shaft(s).

NOTE: All driveline components should be examined before starting any repair.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged, can be caused by:

High engine idle speed. Transmission shift operation. Loose engine/transmission/transfer case mounts. Worn U-joints/CV joint. Loose spring mounts. Loose pinion gear nut and yoke. Excessive ring gear backlash. Excessive side gear to case clearance.

To determined the source of a snap/clunk noise, raise vehicle on a hoist with the wheels free to rotate. Have a helper shift the transmission into gear and listen for the noise.

DIAGNOSTIC CHART

Condition	Possible Causes	Correction
Wheel Noise	1. Wheel loose.	1. Tighten loose nuts.
2. Worn wheel bearing.	2. Replace bearing.
Axle Shaft Noise	1. Misaligned axle tube.	1. Inspect axle tube alignment.

Correct as necessary. 2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle. 3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Grabbing clutch. 4. Replace broken shaft and inspect and repair clutch as necessary.

Differential Cracked        1. Improper adjustment of the       1. Replace case and inspect gears
                            differential bearings.              and bearings for further damage.

                            3. Excessive spinning of one        3. Replace scored gears. Inspect
                            wheel/tire.                         all gears, pinion bores, and shaft

                            4. Worn pinion seal.                4. Replace seal.
                            5. Worn/scored yoke.                5. Replace yoke and seal.

6. Axle cover not properly sealed. 6. Remove, clean and seal cover.

Axle Overheating            1. Lubricant level low.             1. Fill differential to correct level.
                            2. Improper grade of lubricant.     2. Fill differential with the correct

damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation. 3. Ice-spotted pavement. 3. Replace gears and examine remaining parts for damage. 4. Improper adjustments. 4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct. Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity.

                    2. Improper ring gear and pinion   2. Check ring gear and pinion
                    adjustment.                        contact pattern. Adjust backlash or

pinion depth.

                    3. Unmatched ring gear and         3. Replace gears with a matched
                    pinion.                            ring gear and pinion.
                    4. Worn teeth on ring gear or      4. Replace ring gear and pinion.

pinion.

                    5. Loose pinion bearings.         5. Adjust pinion bearing pre-load.
                    6. Loose differential bearings.   6. Adjust differential bearing pre-

load. 7. Ring gear run-out. 7. Measure ring gear run-out. Replace components as necessary. 8. Loose differential bearing cap 8. Inspect differential components bolts. and replace as necessary. Ensure that the bearing caps are torqued to t specifications. 9. Housing not machined properly. 9. Replace housing.

PINION GEAR DEPTH VARIANCE📷 1

Original Pinion Gear	Replacement Pinion Gear Depth Variance
Depth Variance	-4	-3	-2	-1	0	+1	+2	+3	+4
+4	+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001	0
+3	+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001	0	-0.001

+2	+0.006	+0.005	+0.004	+0.003	+0.002	+0.001	0	-0.001	-0.002
+1	+0.005	+0.004	+0.003	+0.002	+0.001	0	-0.001	-0.002	-0.003
0	+0.004	+0.003	+0.002	+0.001	0	-0.001	-0.002	-0.003	-0.004
-1	+0.003	+0.002	+0.001	0	-0.001	-0.002	-0.003	-0.004	-0.005
-2	+0.002	+0.001	0	-0.001	-0.002	-0.003	-0.004	-0.005	-0.006
-3	+0.001	0	-0.001	-0.002	-0.003	-0.004	-0.005	-0.006	-0.007
-4	0	-0.001	-0.002	-0.003	-0.004	-0.005	-0.006	-0.007	-0.008

PINION DEPTH MEASUREMENT📷 4

Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take

measurements with Pinion Gauge Set 6730 and Dial Indicator C-3339A (1).

1. Assemble Pinion Height Block 6739 (2), Pinion Block 8540 (1) and rear pinion bearing onto Screw 6741. 2. Insert assembled height gauge components, rear bearing and screw into housing through pinion bearing cups.

3. Install front pinion bearing and Cone-Nut 6740 on the screw. Tighten Cone-Nut until Torque To Rotate screw is 1.7 N.m (15 in. lbs.). 4. Place Arbor Disc 8541 (1) on Arbor D-115-3 (3) in position in the housing side bearing cradles. Install differential bearing caps on arbor discs and tighten cap bolts to 41 N.m (30 ft. lbs.).

5. Assemble Dial Indicator C-3339A (3) into Scooter Block D-115-2A (2) and secure set screw. 6. Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion height block. Hold scooter block in place and zero the dial indicator. Tighten dial indicator face lock screw. 7. Slowly slide the dial indicator probe over the edge of the pinion height block. 8. Slide the dial indicator probe across the gap between the pinion height block and the arbor bar (1) with the scooter block against the pinion height block. When dial probe contacts the arbor bar, the dial pointer will turn clockwise. Continue moving the dial probe to the crest of the arbor bar and record the highest reading. If the dial indicator can not achieve a zero reading, the rear bearing cup or the pinion depth gauge set is not installed correctly. 9. Select a shim equal to the dial indicator reading, plus the drive pinion gear depth variance number marked on the shaft of the pinion. If the depth variance is -2, add 0.002 in. to the dial indicator reading. If the depth variance is -2, add 0.002 in. subtract dial indicator reading. Then subtract 0.041 mm (0.0016 in.) from the total measurement. This will be the correct pinion height shim selection.

10. Install pinion gear and establish Pinion Torque To Rotate (PTTR) with an inch pound torque wrench (1).

DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH📷 3

1. Turn each thread adjuster inward with Wrench C-4164 until differential bearing end-play is eliminate and ring gear backlash is approximately 0.25 mm (0.01 in.). Seat bearing cups by rapidly rotating the pinion gear a half turn back and forth several times. 2. Install Dial Indicator C-3339A (1) with plunger position against drive side of a ring gear (2) tooth. Measure and record backlash at 4 positions, 90 degrees apart around the ring gear.

Mark lowest backlash position on the ring gear and make all backlash measurements at this location.

3. Loosen left-side adjuster and tighten right-side threaded adjuster with Wrench C-4164 (3) to obtain a backlash of 0.076 - 0.102 mm (0.003 - 0.004 in.). 4. Tighten both adjusters to 14 N.m (10 ft. lbs.). Seat differential bearing cups by rapidly rotating the pinion gear a half turn back and forth several times. 5. Tighten differential bearing cap bolts 95 N.m (70 ft. lbs.). 6. Tighten right-side threaded adjuster to 102 N.m (75 ft. lbs.). Seat differential bearing cups by rapidly rotating the pinion gear a half turn back and forth several times. Continue this procedure until right-side adjuster torque remains a constant 102 N.m (75 ft. lbs.). 7. Measure the ring gear backlash. Backlash should be 0.12 - 0.20 mm (0.005 - 0.008 in.).

If backlash is less than 0.12 (0.005 in.) increase right-side threaded adjuster torque until specified backlash is obtained.

If backlash is more than 0.20 (0.008 in.) repeat procedure from the beginning.

8. Tighten left-side threaded adjuster to 102 N.m (75 ft. lbs.). Seat differential bearing cups by rapidly rotating the pinion gear a half turn back and forth several times. Continue this procedure until left-side adjuster torque remains a constant 102 N.m (75 ft. lbs.). 9. Install threaded adjuster locks and tighten the lock screws to 10 N.m (90 in. lbs.).

10. Measure and backlash at 4 positions, 90 degrees apart around the ring gear. Maximum ring gear backlash variation is 0.076 mm (0.003 in.).

After backlash is achieved, perform Gear Contact procedure.

GEAR CONTACT PATTERN📷 6

1.   Wipe clean each tooth of the ring gear.
  2.   Apply gear marking compound to all of the ring gear teeth.
  3.   Verify bearing cap bolts are torque specifications.
  4.   Apply parking brakes lightly to create at 14 N.m (10 ft. lbs.) pinion rotating torque.
  5.   Rotate the pinion/pinion yoke 4 full revolutions in each directions.
  6.   Read gear tooth contact pattern.

Gear contact pattern is correct. Backlash and pinion depth is correct.

Ring gear is too far away from the pinion gear, coast side toe (1) drive side heel (2). Decrease backlash by moving ring closer to the pinion gear using the adjusters.

Ring gear is too close to the pinion gear, drive side toe (1) coast side heel (2). Increase backlash by moving ring away from the pinion gear using the adjusters.

Ring gear is too far away from the pinion gear, drive side heel (1) coast side heel (2). Decrease backlash by moving ring gear closer to the pinion gear using the adjusters.

Ring gear is too close to the pinion gear, drive side toe (1) coast side toe (2). Increase backlash by moving ring gear away from the pinion gear using the adjusters.

Pinion gear is set too low. Increase pinion gear height, by increasing pinion depth shim thickness.

Pinion gear is set too high. Decrease pinion height by decreasing the pinion depth shim thickness.

AXLE SHAFT END-PLAY📷 1

Visual inspect differential case, pinion mate shaft, axle shaft end button, C-lock, differential pinion gears, differential side gears and washers for damage or excessive wear. Replace damaged components.

1. Assemble differential and install. 2. Install differential pinion mate shaft locking screw to locate the shaft without torque it down. 3. Mount dial indicator base on the axle tube flange. 4. Push axle shaft inward until its end touches differential pinion mate shaft. Set dial indicator plunger on the end of axle shaft flange surface and zero dial indicator. 5. Pull axle shaft out until it stops and record dial indicator end-play reading. Rotate axle shaft about 180 degrees and record dial indicator end-play reading again. Two readings should be within 0.05 mm (0.002 in.). 6. Conduct the same procedure on the axle shaft on the opposite side.

End-play specifications should be 0.13 - 0.38 mm (0.005 - 0.015 in.). If specifications can not be met, shim side gears and/or replace differential case.

DESCRIPTION SPECIFICATION📷 25

Axle Ratio                                             3.21/3.73
          Differential Case Flange Runout                             0.076 mm (0.003 in.)
            Differential Case Clearance                                0.12 mm (0.005 in.)
                Ring Gear Diameter                                      213 mm (8.25 in.)
                Ring Gear Backlash                             0.12 - 0.20 mm (0.005 - 0.008 in.)
                 Ring Gear Runout                                      0.12 mm (0.005 in.)
    Pinion Torque To Rotate - Original Bearings                   1 - 2.2 N.m (10 - 20 in. lbs.)
      Pinion Torque To Rotate - New Bearings                      1 - 3.4 N.m (10 - 30 in. lbs.)

Torque

DESCRIPTION	N.m	Ft. Lbs.	In. Lbs.
Differential Cover Bolts	41	30	-
Bearing Cap Bolts	135	100	-
Ring Gear Bolts	122	90	-
Pinion Nut Minimum	285	210	-
Pinion Mate Shaft Screw	26	19	-
Axle Damper	61	45	-
Adjuster Lock Screw	26	19	-

Ring Gear Bolts - Diesel Engines: Follow service procedure to tighten ring gear bolts on vehicles equipped with diesel engine and 3.21 gear ratio.

Special tools

COVER-DIFFERENTIAL

+15 more figures in this topic

SEAL-PINION📷 5

1.   With vehicle in neutral, position vehicle on hoist.
  2.   Remove wheel and tire assemblies.
  3.   Mark a reference line across the axle flange (1) and propeller shaft flange (2).
  4.   Remove companion flange bolts and remove propeller shaft.
  5.   Remove brake calipers and rotors to prevent any drag.

6. Rotate companion flange three or four times and verify flange rotates smoothly.

7. Record pinion torque to rotating (1) with an inch pound torque wrench (2) for installation reference.

8. Hold pinion flange (1) with Holder C-3281 (2) and remove pinion nut. 9. Mark a line across the pinion shaft and flange for installation reference.

10. Remove pinion flange (1) with Puller 8992 (2). 11. Remove pinion seal with a seal puller.

SEAL-PINION📷 4

1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal with Installer C-4076-B (1) and Handle C-4735 (2).

3. Install flange on the pinion shaft with the reference marks aligned.

4. Install flange (1) with Installer C-3718 (2).

5. Install new pinion nut. Hold flange (1) with Holder C-3281 (2) and tighten pinion nut to 285 N.m (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated.

NOTE: Do not exceed the minimum torque 285 N.m (210 ft. lbs.) when installing the pinion nut at this point.

6. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotating should be equal to recorded reading plus an additional 0.56 N.m (5 in. lbs.).

If pinion torque to rotate is low, tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotating is achieved.

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle.

7. Install propeller shaft (1) with axle flange (2) installation reference marks aligned. 8. Install rear brake components.

DIFFERENTIAL

GEAR-PINION/RING📷 1

NOTE: The ring and pinion gears are serviced in a matched set. Never replace one gear without replacing the other matched gear.

RING GEAR REMOVAL - GAS ENGINE📷 1

1.   Remove differential from axle housing.
  2.   Place differential case in a vise with soft metal jaw.
  3.   Remove bolts (1) holding ring gear (2) to differential case.
  4.   Drive ring gear from differential case with a dead-blow hammer.

RING GEAR REMOVAL - DIESEL ENGINE📷 10

1. Remove differential from axle housing. 2. Place differential case in a vise with soft metal jaw. 3. Remove left hand threaded bolts (1) holding ring gear (2) to differential case.

4. Press ring gear (1) off differential with Plug 8926-2 (2) and Remover 10126-1 (3).

5. Hold pinion flange (1) with Holder C-3281 (2) and remove flange nut.

6. Remove pinion flange (1) from pinion shaft with Puller 8992 (2).

7. Remove pinion (1) from the housing with Driver 8976 (2) and hammer. 8. Remove pinion shaft seal with a seal puller. 9. Remove front pinion bearing.

10. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171 (2).

11. Remove rear bearing cup with Remover C-4307 (1) and Handle C-4171 (2).

12. Remove collapsible spacer (1) from pinion shaft (3).

Adapters C-293-47

13. Remove rear pinion bearing from pinion shaft (1) with Puller/Press C-293-PA (2) and Adapters C-293-47 (3).

14. Remove depth shims (1) from the pinion shaft (2) and record the shims thickness.

GEAR-PINION/RING📷 8

NOTE: A pinion depth shim is located under the rear pinion bearing. If ring and pinion gears are reused, the original pinion depth shim/oil baffle can be used. Refer to PINION DEPTH MEASUREMENT to select the proper shim thickness if ring and pinion gear are replaced.

1. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (2).

2. Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171 (2).

3. Install pinion front bearing in housing. 4. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer C-4076-B (1) and Handle C-4735 (2).

5. Install pinion depth shim (1) on pinion shaft (2).

6. Install rear bearing (4) on pinion gear (3) and slinger if equipped, with Installer 6448A (2) and a press (1).

7. Install a new collapsible spacer (1) on pinion shaft (3) and install pinion in housing.

8. Install pinion flange (1) with Installer C-3718 (2). 9. Install a new nut on the pinion. 10. Holding flange (1) with Holder C-3281 and tighten nut with torque wrench to 285 N.m (210 ft. lbs.).

NOTE: Do not exceed the minimum torque 285 N.m (210 ft. lbs.) when installing the pinion nut at this point.

11. Measure pinion torque to rotating (1) with an inch pound torque wrench (2). Measure pinion torque to rotating frequently to avoid over over-crushing the collapsible spacer.

Pinion Torque To Rotate is:

Original Bearings 1 - 2.2 N.m (10 - 20 in. lbs.) New Bearings 1- 5 N.m (10 - 30 in. lbs.)

If pinion torque to rotate is low, tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotate is achieved.

CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded a new collapsible spacer must be installed. Failure to follow these instructions will damage the axle.

RING GEAR INSTALLATION - GAS ENGINES

1. Install ring gear on differential case. 2. Invert differential case in the vise. 3. Install new ring gear (2) bolts (1) and alternately tighten to 122 N.m (90 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.

4. Install differential in axle housing and verify gear mesh refer to GEAR CONTACT PATTERN.

RING GEAR INSTALLATION - DIESEL ENGINES📷 6

WARNING: Use welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: A bearing heater is used to install the ring gear on the differential. Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 107 - 121 Celsius (225° Min. - 250° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for and extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

1. Heat ring gear (1) on bearing heater (2) to 107 - 121 Celsius (225° Min. - 250° Max Fahrenheit).

2. Turn ring gear over on bearing heater with welding gloves once the temperature has been reached. 3. Install left hand threaded Pins 10126-2 (1) into ring gear (2).

4. Install ring gear (1) on differential (2) using Pins 10126-2 (3) to align ring gear bolts hole.

5. Allow ring gear time to cool, then turn the differential over and remove Pins 10126-2 (1) from ring gear (2).

6. Install new left hand threaded ring gear (2) bolts (1) and alternately tighten to 27 N.m (20 ft. lbs.). Then with torque angle gauge alternately tighten to 95 degrees ± 5 degrees.

CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.

7. Install differential in axle housing and verify gear mesh refer to GEAR CONTACT PATTERN.