Overhaul (Gear-Pinion/Ring)
GEAR-PINION/RINGREMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one without replacing the other.
1. Remove differential from housing.
2. Place differential case (1) in a vise with soft jaw.
3. Remove bolts holding ring gear to differential case.
4. Drive ring gear (2) from differential case (1) with a soft hammer (3).
5. Mark 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 (1) three or four times and verify flange rotates smoothly.
8. Record pinion rotating torque an inch pound torque wrench (2) for installation reference.
9. Install bolts into two of the threaded holes in the companion flange 180° apart.
10. Position Holder 6719 against the companion flange (1) 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 C452 (2).
13. Remove pinion from differential housing.
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 8831 (2) and Handle C4171 (3).
17. Remove rear pinion bearing cup from housing (1) with Remover 8401 (2) and Handle C4171(3).
18. Remove collapsible spacer (1) from pinion.
19. Remove rear pinion bearing with Puller/Press C293PA (1) and Adapters C29342 (3).
20. Remove depth shims from 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 matching gear. If ring and pinion gears or bearings are replaced, Adjust 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 8692 (2) and Handle C4171 (3).
3. Install front pinion bearing cup with Installer 8693 and Handle C4171.
4. Lubricate front pinion bearing and install bearing in the housing.
5. Apply a light coating of gear lubricant on the lip of pinion seal.
6. Install pinion seal with Installer 8695 (2) and Handle C4171 (1).
7. Place pinion depth shim (1) on the pinion shaft (2).
8. Install rear pinion bearing (4) with Installer 6448A (2) and a press (1).
9. Install new collapsible spacer (1) onto the pinion shaft.
10. Lubricate rear pinion bearing and install the pinion gear in the housing.
11. Install companion flange with Installer C3718 and Holder 6719 (2).
12. Install new pinion nut and tighten to 271 Nm (200 ft. lbs.).
13. Using Holder 6719 and a torque wrench set at 475 Nm (350 ft. lbs.). Tighten pinion nut until bearing end play is taken up.
14. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until Torque To Rotate is achieved. Measure Torque To Rotate frequently to avoid overcrushing the collapsible spacer. The pinion Torque To Rotate is:
^ Original Bearings: 1 to 2.5 Nm (10 to 20 inch lbs.)
^ New Bearings: 2.0 to 2.8 Nm (18 to 25 inch lbs.)
CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.
15. Invert differential case (4) and start two ring gear (3) bolts to provide ring gear bolt hole alignment.
16. Invert differential case in the vise.
17. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.).
CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction will result in damage.
18. Install differential in housing and verify gear mesh, backlash and contact pattern