[moosejaw]

This post refers to 8.8 gears.

When using FRPP gears usually no changes need be made except for 4.10 gears. 4.10 gears usually need about .002 taken off the pinion shim. Some ring gears need to be lightly sanded on the I.D. to help slip on the carrier. Don't overtorque ring gear bolts i.e. no impacts allowed.

Replacing carrier bearings is a bear without the proper tools. Only replace if you have the proper tools. Clamshell pullers and a hydraulic press are a must for the pinion.

If using other than FRPP gears Pinion depth needs to be checked.

You need a new pinion nut. Use the old nut to hammer out the pinion. Some years need to be hammered really hard to get the pinion free of the front bearing.

You will need the strongest breaker bar and long pipe to get the proper preload on the pinion crush sleeve. Pu Proper preload is achieved when there is just enough drag on the pinion to spin it no more than one turn.

Backlash should be about .006" to .012" or what ever looks right to you . But as a minimun the gears should turn free with caps torqued down with some play.

Blue check the gears with some lithium grease in the drive and coast conditions. Just imagine acceleration and coast and simulate that by hand. Tooth contact should be centered and full width of tooth. Centered contact is most important .

Mike