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To change the pinion gear in a differential you must first open the differential, drain the gear oil and inspect the gears and bearings. Pinion gears and ring gears are usually done as a matched set so you should plan on replacing both.

Remove the axle shafts and then mark the carrier bearing caps so they can be replaced in exactly the same location and direction that they came off. remove the caps and then pull the carrier out.

Measure the pinion to axle centerline distance so that you can get the new pinion in the same spot. Remove the yoke retainer nut and the driveshaft yoke and then remove the pinion from the differential housing. You should be using new bearings and races so remove the old races from the differential housing and the old bearing from the Pinion gear. The shims from the old gear should be a good starting place to set up your new pinion depth. Test fit the new pinion to see if the pinion depth is right. Install pinion bearing races, bearings and new seal. Install new ring gear and set the gear lash You may have to shim the carrier or change the pinion depth to get the right gear lash.

This process usually requires expert knowledge and specialized tools and you may want to consult a qualified mechanic to do the job. There are many more detailed descriptions on the net.

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14y ago

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