[jjmt]

DO NOT MIX THE CAPS!! MARK EM AS YOU TAKE EM OFF so you know what side they came off (pic68 and 69) THIS IS VERY IMPORNENT!!!
Now the carrier is ready to come out (pic71)
Grab it and wiggle it out and catch the shims as they come out with it (pic72) DO NOT MIX THE BEARING RETANERS MAKE SURE THAT YOU MARK THEM AS TO WHAT SIDE OF THE CARRIER THAY CAME OFF FROM!!!!!(pic73)

[BoostNStang4.0]

dude this is awesome...where have you been all my life lol......but really nice job and keep it coming

[jjmt]

Now the ring gear will come out (pic74) the support bar will move out of your way when you touch it with the carrier (pic75) now its out (pic76) now I set in the bearing retainer so I can remove the ring gear bolts (pic77) I toke out the traction-loc clutches to inspect them (pic78) YOU WILL NOT NEED TO DO THAT I JUST WANTED TO SEE HOW IT WORKED!!

[jjmt]

Everything was good no wear on the carbon fiber clutches cleaned it up a little (pic79)
Clean the carrier housing (pic80) and tap out the pinion gear with a small hammer (pic81) it came out pretty ez.
Now remove the old seal and front pinion bearing and the oil slinger (pic82) I used a cut down broom stick cut to 18 inches long and taped it out from behind (pic83)

[jjmt]

Once the front seal was out the bearing just falls right out (pic84 and 85 and 86)
Now clean the front race with a towel to clean up any wood that I might have left from knocking out the seal(pic87 and 88)

[jjmt]

Now that’s done get back to carrier and remove the old ring gear (pic89 and 90)
Once you have all the bolts off the ring will just fall off with a light tap to the side with the wrench (pic91) now I reinstalled the traction-loc clutches and spider gears (pics94 and 95)

[jjmt]

The old ring and pinion on the left and the 4:10s on the right(pic96) I used the supplied thread lock on all of the ring gear bolts (pic99) then wrench the bolts down (pic100)
Then put the carrier in the vise between 2 pieces of wood and torque the ring gear bolts to 85 foot pounds (pic101) now set carrier with the new ring aside (pic102)

[jjmt]

Now grab the pinion with a towel or heavy glove(pic103) and hit the threaded end on something hard like the vise or the floor and the bearing will come off (pics 104-105-106 and 107)or you can take it to shop to press it off!

[jjmt]

While the bearing is cooling off clean the inside of the differential case with clean towels
(pic108 and 109)and now brake out the dial calipers cause you will need it to measure the width of the stock pinion gear and the new pinion gear(pic110and 111)the reason you do this is because the is a shim between the bearing and the back of the pinion gear. The stock pinion was 1.878 and the new pinion was 1.866 a difference of .012 smaller and the shim on the stock pinion .020 thick so I put a .030 thick shim on (pic112) so that the pinion setting depth would be within .005 this is another very important step to do because it sets the centering of the pinion gear to the ring gear to maintain maximum gear to gear contact on the heel and the toe of the gears. This dimension will be checked agine when the pinion is installed into the differential… NOTE EVERY CAR IS GOING TO BE DIFFERENT

[jjmt]

Now put the new shim on the new pinion then heat up the bearing a little to expand it so that it will go onto the pinion shaft (pic114)make sure that you put the bearing on the right way (the big end of the bearing goes up against the pinion gear) with the shim in place and the bearing still hot steel rod to TAP the bearing down into place (pic115) the bearing should be tight up against the gear (pic116) now look at the face of the pinion gear (pic117) see the numbers? 2.5489” that is the setting depth of the pinion. Write it down!
Now put the pinion back into the differential (pic118) be careful not to hit the bearing race as you put the pinion back in..

[jjmt]

Now push the pinion into the bearing race (pic120) and hold it in with your hand and then
Place the new CRUSH spacer on the pinion (pic121) then the bearing (pic122) and (dip the bearing in oil before putting it in) now the slinger (PIC123) and then the new seal (pic124)

[jjmt]

Now tap the seal into the differential case (pic125) do not beat it in just tap it in..now put the yoke on (pic126) Now put the new pinion nut on (pic127) now wrench the nut down as you can go with the ratchet (pic128) IT’S GONNA BE F#%&KING HARD to tighten it down! That’s what the wrench on the 2 bolts were there fore. To hold the yoke from spinning around. Get it as tight as you can with the ratchet then get the torque wrench and TORQUE the nut to 140 foot pounds (pic129)

[jjmt]

Now look at (pic129a) that flat is where the bearing cap bolts to, that is the center line which is the center of the ring gear and the axles this where the pinion setting depth is measured from(remember that number 2.5489” that was etched on the pinion face)
Now I made a plate from a pice of scrap metal that measured .260” thick. I drilled holes in varies places and two 1/2inch holes at one end and then bolt it to the case (pic 130) Now get the dial caliper and position it with the depth measuring side on the plate (pic130a) now slide the caliper open with the depth rod going though the hole on the plate (pic131) keep sliding it till the depth rod touches the pinion face while at the same time making sure the caliper body is firmly against the plate. Now look at the dial face take the measurement (pic132) I got 2.813” now I did that five times to get an average cause I would get 2.810” then 2.814” then 2.812” then 2.813” then 2.815” =14.064/5= 2.8128” so I rounded it off to 2.813. now subtract the plate thickness of .260” from the 2.813” which is 2.553” my target depth is 2.549 with the .030” shim I ended up with a pinion depth of 2.553” well with in the .010” tolerance which is 2.4589 plus or minus .010 which means as long as I was in between 2.539 and 2.559 I am good to go.

[jjmt]

Now remove the plate and clean the pinion gear and inside of the case (pic133) and (pic134) now put oil the bearing and on the races then set them on the carrier bearings (pic135 and 139). You did mark em to what side they came off RIGHT?
Now the carrier is ready to be installed in the differential case(pic137)

[jjmt]

Make sure that the bearing seats in the diff. case are clean (pic140) and the pinion gear is clean also (pic141) now hold the carrier with the bearing races in place and slide it into place (pic142) you may have to “jiggle” it a little to get the ring gear to go on the pinion gear.now put the shims back in.(pic143) and put the bearing caps on and sung em down then the dial indicator with magnet base (pic143a)