- Inspect drive pinion bearings and outer races. If necessary, replace drive pinion bearing and outer race using a press to drive pinion from bearing.
NOTE:
If drive pinion or ring gear is damaged, replace both as a set.
- For drive pinion, select a plate washer of proper thickness, in accordance with teeth contact, inspected before disassembly. Install plate washer on drive pinion. Using a press, install NEW bearing on drive pinion.
- Using a hammer and brass bar, remove pinion outer races by tapping on notched portions. Using a bearing race installer, install outer races.
- Inspect case side bearings and outer races. If necessary, replace side bearings and outer races by removing side bearings with a gear puller. The hooked ends of the puller fit into the indentations in the case. Install NEW bearings using a press.
- Inspect pinion and side gears. Check side gear backlash by holding one side gear toward case and measuring backlash of the other. Backlash should be .0016-.0094" (.04-.24 mm).
- If it becomes necessary to replace ring gear, differential pinions and side gears, then lift lock plates and remove set bolts. Using a brass bar and hammer, tap on ring gear to separate it from differential case.
NOTE:
If the ring gear is to be used again, before separating it, place marks on ring gear and case for reference at reassembly.
- Using a pin punch and hammer, tap out pinion shaft retaining pin toward ring gear mating surface. Remove pinion shaft, pinion gears, side gears and thrust washers. Check gears, shaft, case and washers.
- Install side gears, washers, pinion gears and shaft. Re-measure side gear backlash. If backlash is not within specifications, use proper thickness thrust washer to bring backlash within specifications. Thrust washers are available in thicknesses ranging from .0583-.0697" (1.48-1.77 mm) in increments of .0015" (.04 mm).
- Using a hammer and punch, drive straight pin through case and hole in pinion shaft. Stake pin in place in differential case. Clean ring gear mating surface on case. Heat ring gear to 194-230°F (90-110°C) in an oil bath. Then quickly install ring gear on differential case.
CAUTION:
DO NOT
heat ring gear above 230°F (110°C).
- Coat ring gear bolts with gear oil. Install lock plates and bolts. Tighten bolts uniformly, in steps and to specifications. Stake lock plate.
NOTE:
Stake one claw flush with flat surface of nut. For claw contacting protruding portion of nut, stake (bend) only the half on the tightening side.
- Inspect governor pressure adapter oil seal. If necessary, replace oil seal using a press and a 29 mm socket wrench. Press in oil seal on transmission side then press in oil seal on differential side. Be sure oil seal is positioned correctly.