Installation

INSTALLATION

WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

1. Heat rear pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install on pinion with tongs or welding gloves. Use Installer MD998805 to ensure that the pinion bearing is seated tightly against the pinion head.
2. Apply Mopar Door Ease or equivalent lubricant to outside surface of bearing cups.
3. Install pinion depth shim in rear pinion bearing cup bore.
4. Install rear pinion bearing cup with Bearing Cup Installer 8959 and Universal Drive Handle C-4171.
5. Install front pinion bearing cup with Bearing Cup Installer 10127 and Universal Drive Handle C-4171.

6. Install pinion spacer (1) on pinion shaft (2).

7. Install new collapsible preload spacer (1) on pinion shaft (2) and install pinion gear into the housing.

CAUTION: Be sure that the front pinion bearing has cooled sufficiently before installing the pinon seal.

9. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer 10003 (2).
10. Hold pinion flange with Flange Wrench C-3281.
11. Screw on the new collared nut.
12. Tighten collar nut carefully to achieve a pinion torque to rotate of 2.5 - 3 Nm (22 - 27 in. lbs.).

13. Cut the collar of the tightened collared nut.

14. Bend collar (1) so it touches the wall of the slot in the pinion shaft.
15. Install differential in axle housing and verify gear mesh and contact pattern.