You will need to replace the ring and pinion gears as a set. You will also need to replace the bearings for both the carrier and pinion. You can buy a bearing kit that includes bearings, pinion seal, shims, crush sleeve and ring gear bolts for about 100 bucks. The ring and pinion gear set will cost around 150. While you're at it, if it doesn't already have a locking differential, you should plan on replacing it. That will be the most expensive item, at around 400 bucks, but replacing the differential solves the problem of removing the ring gear and carrier bearings, which aren't easy to remove if you don't have the right tools. If the vehicle has over 100K on it, you should probably replace the wheel bearings and seals, which will total around 100 bucks.
Tools: Foot-lb torque wrench (needs to work both clockwise and counter-clockwise) Inch-lb torque wrench (for pinion bearing preload) Dial indicator (for adjusting gear backlash). Impact wrench, or 1/2" or 3/4" drive ratchet with big cheater bar (pinion nut needs about 300 ft-lbs to crush the sleeve) Slide hammer (if you're replacing the wheel bearings) Carrier bearing puller (if you're NOT replacing the differential) Gas barbecue (to heat the ring bearing prior to installation; kitchen oven also works if you're a bachelor) Pipe wrench with big cheater bar (to hold the pinion yoke while setting preload)
If you've read this far and still think you want to tackle it, here are some tips: 1. Technically, you're supposed to set the pinion depth, which requires a special fixture. In practice, you can get away with just re-using the old pinion shim stack. 2. The ring gear bolts are left-hand thread. 3. The ring gear must be heated in order to remove it or install it on the differential carrier. 500 degrees F is a good, safe temperature. 4. Setting the pinion preload is very tricky, because once you crush the preload sleeve it can't be uncrushed. As you approach the desired preload, tighten the pinion in very small increments. If you overshoot the target preload, leave it be. 5. Pack the bearings with grease prior to installation. You need lubrication to set the preload properly, and they'll break in a bit in the first few miles.
You WILL need a manual, because nobody is going to tell you all the steps. Check out the DTS site below, you can find all the parts you'll need there, even if you end up buying them locally. Good luck.
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