Differential Pinion Flange/Yoke, Seal, Deflector Repl - Front

Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement - Front

Tools Required
^ J8614-01 Flange and Pulley Holding Tool
^ J33782 Pinion Oil Seal Installer

Removal Procedure
1. Raise the vehicle.
2. Remove the engine protection shield.
3. Remove the front propeller shaft.
4. Remove the rear steering gear crossmember.





5. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components:
^ The pinion bearings
^ The pinion seal
^ The carrier bearings
^ The axle bearings
^ The axle seals





6. Scribe an alignment line between the pinion shaft and the pinion yoke.





7. Install the J8614-01 onto the pinion as shown.
8. Remove the pinion nut while holding the J8614-01.





9. Install the J8614-2 (2) and the J8614-3 (3) into the J8614-01 (1) as shown.
10. Remove the pinion yoke by turning the J8614-3 (3) clockwise while holding the J8614-01 (1).

Important: Carefully remove the seal from the bore. Do not distort or scratch the aluminum case.

11. Remove the oil seal using a suitable seal removal tool.





12. Remove the dust deflector from the pinion yoke using a soft-faced hammer.

Installation Procedure





1. Install the new deflector onto the pinion yoke using a soft-faced hammer.

Important: Drive the seal in straight, not at an angle, as this will damage the aluminum housing.

2. Install the new oil seal by doing the following:
2.1. Position the oil seal in the bore.
2.2. Install the J33782 over the oil seal.
2.3. Strike the J33782 with a hammer until the seal flange seats on the axle housing surface.
3. Apply sealant to the splines of the drive pinion yoke.
4. Install the pinion yoke.
Align the reference marks made during removal.

Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft.





5. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke.
6. Install the washer and a new pinion nut.





7. Install the J8614-01 onto the pinion yoke as shown.

Notice: Refer to Fastener Notice in Service Precautions.

Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed.

8. Tighten the pinion nut while holding the J8614-01.
Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings.
9. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement of the rotating torque to the measurement recorded earlier.
Specification
The rotating torque of the pinion nut should be 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the torque recorded during removal.
10. If the rotating torque is not within specifications, continue to tighten the pinion nut.
Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than the torque recorded during removal.
11. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated, Recheck the rotating torque and adjust if necessary.
12. Install the rear steering gear crossmember.
13. Install the front propeller shaft.
14. Install the engine protection shield.
15. Inspect the axle lubricant level, and add, if necessary.
16. Lower the vehicle.