Ring and Pinion
C205F Front Axle - Pinion Gear/Ring Gear/Tone RingREMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear.
1. Remove differential from axle housing.
2. Place differential case in a vise with soft jaw (Fig. 34).
3. Remove bolts holding ring gear to differential case.
4. Drive ring gear from differential case with a soft hammer (Fig. 34).
5. Mark the companion yoke and companion flange for installation reference.
6. Remove companion flange bolts and tie the propeller shaft to the vehicle underbody.
7. Rotate companion flange three or four times and verify flange rotates smoothly.
8. Record pinion rotating torque an inch pound torque wrench for installation reference (Fig. 35).
9. Install bolts into two of the threaded holes in the companion flange 180° apart.
10. Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so that the Holder 6719 is held to the flange.
11. Remove the pinion nut.
12. Remove the companion flange with Remover C-452 (Fig. 36).
13. Remove pinion from differential housing (Fig. 37).
14. Remove pinion seal with a pry tool or a slide hammer mounted screw.
15. Remove oil slinger, if equipped, and front pinion bearing.
16. Remove front pinion bearing cup with Remover D-103 and Handle C-4171 (Fig. 38).
17. Remove rear pinion bearing cup from housing (Fig. 39) with Remover 8401 and Handle C-4171.
18. Remove collapsible preload spacer (Fig. 40).
19. Remove rear pinion bearing with Puller/Press C-293-PA and Adapters C-293-42 (Fig. 41).
20. Remove depth shims from the pinion shaft and record thickness of shims.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. If ring and pinion gears or bearings are replaced, refer to Adjustments for Pinion Gear Depth Setting.
1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the bearing cups.
2. Install rear pinion bearing cup with Installer D-145 and Driver Handle C-4171 (Fig. 42) and verify cup is seated.
3. Install front pinion bearing cup with Installer D-129 and Handle C-4171 (Fig. 43) and verify cup is seated.
4. Install pinion front bearing and oil slinger if equipped.
5. Apply a light coating of gear lubricant on the lip of pinion seal.
6. Install pinion seal with Installer C-3972-A and Handle C-4171 (Fig. 44).
7. Place the proper thickness depth shim (Fig. 45) on the pinion shaft.
8. Install rear bearing and slinger if equipped, onto the pinion shaft with Installer 6448 (Fig. 46) and a press.
9. Install new collapsible preload spacer onto the pinion shaft (Fig. 47).
10. Install the pinion gear in the housing.
11. Install the companion flange with Installer C-3718 and Holder 6719.
12. Install new pinion nut and tighten to 271 Nm (200 ft. lbs.) (Fig. 48).
13. Using Holder 6719 and a torque wrench set at 474 Nm (350 ft. lbs.). Tighten pinion nut until bearing end play is taken up.
14. Slowly tighten the nut in 3.5 Nm (5 ft. lbs.) increments until desired rotating torque is achieved. Measure the rotating torque frequently to avoid overcrushing the collapsible spacer (Fig. 49). The pinion rotating torque should be:
- Original Bearings:...........1 to 2.5 Nm (10 to 20 inch lbs.)
- New Bearings:.............1.7 to 2.5 Nm (15 to 22 inch lbs.)
CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
15. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
16. Invert the differential case in the vise.
17. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.) (Fig. 50).
CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.
18. Install differential in axle housing and verify gear mesh and contact pattern.
19. Install differential cover and fill with gear lubricant.
20. Install propeller shaft with reference marks aligned.
21. Remove support and lower vehicle.