Ring and Pinion

GEAR-PINION/RING

REMOVAL

NOTE: The ring gear and pinion are serviced as a matched set. Never replace ring gear without replacing the matched pinion gear.

1. Remove differential from axle housing.





2. Place differential case (1) (Fig. 59) in a vise with soft jaws.
3. Remove bolts holding ring gear to differential case.
4. Driver ring gear (2) off the differential case (1) with a dead-blow hammer (3).





5. With Spanner Wrench 6958 (1) (Fig. 60) and a short length of 1 inch pipe, hold pinion companion flange (2) and remove pinion nut.





6. Remove pinion companion flange from pinion shaft with Spanner Wrench 6958 (1) (Fig. 61) and Remover C-452 (2).





7. Remove pinion gear from housing with deadblow hammer (1) (Fig. 62).





8. Remove front pinion bearing cup, bearing, oil slinger and pinion seal with Remover C-149 (1) (Fig. 63) and Handle C-4171 (2).





9. Remove rear pinion bearing cup with Remover C-4307 (1) (Fig. 64) and Handle C-4171 (2).





10. Remove collapsible spacer (1) (Fig. 65) from pinion gear (3).





11. Remove rear pinion bearing from the pinion (4) (Fig. 66) with Puller/Press C-293-PA (1) and Adapters C-293-42 (3). Remove oil slinger/pinion depth shim from the pinion shaft and record thickness.

INSTALLATION
1. Install front pinion bearing, and oil slinger if equipped.
2. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer 8681.

NOTE: Pinion depth shims are placed between the rear pinion bearing and the pinion gear head to achieve proper ring and pinion gear mesh. If ring and pinion gears are reused, the pinion oil slinger/depth shim should not require replacement. Refer to (Pinion Gear Depth) to select the proper thickness shim before installing pinion gear.

3. Apply Mopar Door Ease or equivalent lubricant to outside surface of pinion bearing cups.
4. Install rear bearing cup with Installer C-4308 and Handle C-4171.





5. Install front bearing cup with Installer D-146 (1) (Fig. 67) and Handle C-4171 (1).





6. Install rear pinion bearing (4) (Fig. 68) and oil slinger/depth shim (2) onto the pinion shaft (3) with Installer 6448 (1) and a press (1).





7. Install a new collapsible spacer (1) (Fig. 69) on pinion shaft 3. and install the pinion into the housing.
8. Install pinion companion flange, with Installer W-162-D, Cup 8109 and Spanner Wrench 6958.
9. Install pinion a new nut onto the pinion gear and tighten the nut to 216 Nm (160 ft. lbs.). Do not over-tighten.

CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.





10. Use Spanner Wrench 6958 (1) (Fig. 70), a length of 1 inch pipe and a torque wrench set at 678 Nm (500 ft. lbs.) and crush collapsible spacer until bearing end play is taken up.
11. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the required rotating torque is achieved. Measure rotating torque frequently to avoid over crushing the collapsible spacer.





12. Rotate the pinion a minimum of ten times. Verify pinion (1) (Fig. 71) rotates smoothly and check rotating torque with an inch pound torque wrench (2). Pinion gear rotating torque is:
^ Original Bearings: 1 to 2.25 Nm (10 to 20 inch lbs.).
^ New Bearings: 1.69 to 2.82 Nm (15 to 25 inch lbs.).
13. Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.





14. Invert differential case (4) (Fig. 72) in the vise. Install new ring gear (3) bolts (2) and alternately tighten to 108 Nm (80 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.

15. Install differential in housing and verify differential bearing preload, gear mesh and contact pattern.