Pinion Gear/Ring Gear
PINION GEAR/RING GEARREMOVAL
NOTE: The ring gear and pinion are serviced as a matched set. Never replace one gear without replacing the other matched gear.
1. Raise and support vehicle
2. Mark pinion yoke and propeller shaft for installation reference.
3. Remove propeller shaft from pinion yoke and tie propeller shaft to underbody
4. Remove differential assembly from axle housing.
5. Place differential case in a vise with soft metal jaw.
6. Remove bolts holding ring gear to differential case.
7. Driver ring gear off the differential case with a rawhide hammer (Fig. 57).
8. Using Spanner Wrench 6958 to hold yoke, remove the pinion nut and washer (Fig. 58).
9. Remove pinion yoke from pinion shaft with Remover C-452 and Flange Wrench C-3281 (Fig. 59).
10. Remove pinion gear and preload shims from housing (Fig. 60).
11. Remove front pinion bearing cup, bearing and pinion seal with Remover D-147 and Handle C-4171 (Fig. 61).
12. Remove rear pinion bearing cup from axle housing with remover D-148 and Handle C-4171 (Fig. 62).
13. Remove depth shims from rear pinion bearing cup bore in differential housing and record the thickness.
NOTE: The pinion depth shims can be very thin. Verify that all shims have been removed before proceeding.
14. Remove rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-48 (Fig. 63).
INSTALLATION
NOTE: Pinion depth shims are placed between the rear pinion bearing cup and axle housing to achieve proper ring and pinion gear mesh. If the ring and pinion gears are reused, the original pinion depth shim can be used. Refer to Adjustments (Pinion Gear Depth) to select the proper shim thickness.
1. Install pinion depth shim in rear pinion bearing cup bore.
2. Apply Mopar Door Ease or equivalent lubricant to the outside surface of pinion bearing cups. Install rear bearing cup with Installer D-145 and Handle C-4171 (Fig. 64) and verify cup is seated.
3. Install front bearing cup with Installer D-144 and Handle C-4171 (Fig. 65) and verify cup is seated.
4. Install front pinion bearing and oil slinger, if equipped.
5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with an appropriate installer (Fig. 66).
6. Install rear pinion bearing and slinger if equipped on the pinion gear with Installer W-262 and a press (Fig. 67).
7. Install pinion bearing preload shims onto the pinion gear (Fig. 68).
8. Install pinion gear into the housing.
9. Install yoke with Installer W-162-13, Cup 8109 and Spanner Wrench 6958 (Fig. 69).
10. Install pinion washer and a new nut hold pinion yoke Spanner Wrench 6958 (Fig. 70) and tighten nut to 217 - 271 Nm (160 - 200 ft. lbs.).
11. Check bearing preload torque with an inch pound torque wrench (Fig. 71). The torque necessary to rotate the pinion gear should be:
- Original Bearings: 1 to 2.26 Nm (10 to 20 in. lbs.).
- New Bearings: 2.26 to 4.52 Nm (20 to 40 in. lbs.).
12. If rotating torque is above the desired amount, remove the pinion yoke and increase the preload shim pack thickness. Increasing the shim pack thickness 0.025 mm (0.001 in.) will decrease the rotating torque approximately 0.9 Nm (8 in. lbs.).
13. If the maximum tightening torque is reached prior to achieving the desired rotating torque, remove the pinion yoke and decrease the thickness of the preload shim pack. Decreasing the shim pack thickness 0.025 mm (0.001 in.) will increase the rotating torque approximately 0.9 Nm (8 in. lbs.).
14. Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
CAUTION: Never reuse ring gear bolts, the bolts can fracture causing extensive damage.
15. Invert differential case in the vise.
16. Install new ring gear bolts and alternately tighten to 95 - 122 Nm (70 - 90 ft. lbs.) (Fig. 72).
17. Install differential in axle housing and verify gear mesh and contact pattern. Refer to Adjustment (Gear Contact Pattern).
18. Install differential cover and fill with fluid.
19. Install propeller shaft with reference marks aligned.
20. Remove support and lower vehicle.