Gasket

degrees apart so that they engage side gears. Rotate gears until pinion shaft holes are aligned. Install pinion shaft and lock screw. It is not necessary to torque lock screw until axle shafts are installed.

Drive Pinion

Rem oval

1. Remove differential as previously outlined. 2. Remove propeller shaft. 3. Install Tool J-8614-1 on pinion flange and remove pinion flange nut and washer (fig. 6A). (Position J-8614-1 on flange so that the four notches are toward flange.)

Discard nut and use a new one upon reassembly. 4. Thread end of Tool J-8614-3 into small O.D. end of

J-8614- 2. Then with J-8614-1 installed as in Step 6, insert J-8614-2 into J-8614-1 and turn it 45 degrees to locked position. Remove flange by turning J-8614-3 while holding J-8614-1 (fig. 7A). 5. Pry old seal out of bore, using a screw driver or a ham m er and chisel. If deflector requires replacement, remove by tapping from flange. Clean up stake points. Install new deflector, and stake deflector at three new equally spaced positions.

NOTE: Staking operation must be performed in such a manner that the seal operating surface is not damaged.

6. Remove drive pinion by tapping on front end with a soft faced hammer. Then remove pinion front bearing cone from carrier bore. D iscard pinion bearing spacer and use a new one upon reassembly.

NOTE: Care must be taken not to damage pinion bearings while removing pinion from carrier. Inspect bearings and cups for damage and replace if needed.

Inspection

1. Clean all gears and bearings in cleaning solvent and inspect all bearing cups, races and rollers for scoring,

Fig. 7A~Drive Pinion Flange Removal

chipping or evidence of excessive wear. On pinion bearing rollers, inspect large end of rollers for wear. This is where wear is most evident on tapered roller bearings.

NOTE: The pinion bearings are of the tapered type, and the natural wear pattern is a frosted condition with occasional slight scratches on races or rollers. This does not indicate a defective bearing.

2. Inspect pinion splines and flange splines for evidence of excessive wear. 3. Inspect ring gear and pinion teeth for possible scoring, cracking or chipping.

Pinion and/or Bearing R ep lacem en t

1. If necessary to replace pinion bearings, tap old cups out of carrier using a brass drift. Tap alternately on opposite sides of cup to prevent cups from cocking in carrier.

Inspect cup seats and bore for any nicks or burrs and remove as necessary. 2. Position new bearing cup in carrier, thick edge of cup

Fig. 6A -D rive Pinion Nut Removal Fig. 8A -D rive Pinion Rear Bearing Cup Installation