Differential Drive Pinion Gear Yoke Replacement (G96)

Single Use Fasteners and Components Differential Drive Pinion Gear Nut Differential Drive Pinion Gear Seal Special Tools DT-52506 Pinion Flange Holder and Remover DT-52904 Pinion Seal Installer Equivalent regional tools: Special Tools Removal

1. Set the parking brake to service mode. Parking Brake Service Mode Selection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 1

3. Rear Propeller Shaft Bolt (1) » Remove [4x]

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 2

4. Propeller Shaft (1) » Remove

Note

Record the measurement for re-assembly.

5. Measure and record 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

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 3

6. Using DT-52506 Pinion Flange Holder and Remover (1), Remove and DISCARD the differential drive pinion gear nut (2).

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 4

Note

Be careful not to damage the slinger when removing the pinion gear yoke assembly.

7. Using DT-52506 Pinion Flange Holder and Remover (2), Remove the differential drive pinion gear yoke (1).

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 5

8. Differential Drive Pinion Gear Seal (1) » Remove and DISCARD Installation

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 6

1. Verify the differential drive pinion gear washer (1) is installed and fully seated against the outer pinion bearing.

2. Using DT-52904 Pinion Seal Installer (2), Install NEW differential drive pinion gear seal (1).

3. Apply grease to the pinion seal where it will contact the pinion gear yoke slinger. Adhesives, Fluids, Lubricants, and Sealers

Note

Be careful not to damage the slinger when installing the pinion gear yoke assembly.

4. Differential Drive Pinion Gear Yoke (1) » Install

5. Prepare the NEW differential drive pinion gear nut (2) for installation as follows: 5.1. Remove all traces of the adhesive patch from the nut and the mating pinion threads using the appropriate tools. 5.2. Clean the threads of the nut and mating pinion threads with denatured alcohol or equivalent and allow to dry. 5.3. Apply thread locking adhesive to the nut. Adhesives, Fluids, Lubricants, and Sealers 5.4. Ensure there are no gaps in the thread locking adhesive once applied to the nut.

Caution

Refer to Torque-to-Yield Fastener Caution.

Caution

Refer to Fastener Caution.

6. Using DT-52506 Pinion Flange Holder and Remover (1), Install NEW differential drive pinion gear nut (2) hand tight.
7. Tighten the differential drive pinion gear nut (2) until the pinion end play is taken up.
8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Continue tightening the differential drive pinion gear nut (2) until specified rotating torque is obtained, refer to Fastener Specifications.
9. 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.

Differential Drive Pinion Gear Yoke Replacement (G96) — figure 7

10. Rear Axle Housing Fill Plug (1) » Remove
11. Inspect the gear lubricant level, it should be 1-2 mm (0.039-0.079 in) below the bottom of the fill plug opening.
12. If the level is low, add gear lubricant until the level is 1-2 mm (0.039-0.079 in) below the bottom of the fill plug opening. Use the appropriate axle lubricant: Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

13. Rear Axle Housing Fill Plug (1) » Install and tighten — Fastener Specifications

14. Propeller Shaft (1) » Install

15. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 15.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 15.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 15.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 15.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

16. Rear Propeller Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

17. Remove the support and lower the vehicle.

18. Release the parking brake from service mode. Parking Brake Service Mode Selection