Rear Axle - 8 1/4
GEAR-PINION/RING/TONE RINGREMOVAL
Note: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the matching gear.
1. Remove propeller shaft.
2. Remove differential from the axle housing.
3. Place differential case in vise with soft metal jaw protectors.
4. Remove ring gear bolts and drive ring gear (2) off differential case with a soft hammer (3).
5. Install bolts into two of the threaded holes in the pinion flange 180° apart.
6. Position Holder 6719 against flange and install a bolt and washer into one of the remaining threaded holes. Tighten bolts so the Holder 6719 is held to the flange.
7. Hold flange with Holder 6719 and remove flange nut and washer.
8. Remove flange (1) with Remover C-452 (2).
9. Remove pinion from housing with a soft hammer (1).
10. Remove pinion seal with a pry tool or slide-hammer mounted screw.
11. Remove oil slinger if equipped and front pinion bearing.
12. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171 (2).
13. Remove rear bearing cup from housing with Remover C-4307 (1) and Handle C-4171 (2).
14. Remove collapsible preload spacer (1) from pinion gear.
15. Remove rear bearing from pinion with Puller/Press C-293-PA (1) and Adapters C-293-47 (3).
16. Remove depth shims (1) from pinion gear (2) and record shim thickness.
INSTALLATION
Note: Ring and pinion gears are a matched set. Do not replace one gear without replacing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting.
1. Apply Mopar Door Ease or stick lubricant to outside surface of pinion bearing cups.
2. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (20).
3. Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171 (2).
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 Installer C-4076-B (3) and Handle C-4735 (1).
6. Install proper thickness depth shim (1) on pinion gear (2)
7. Install rear bearing (4) and slinger if equipped, on pinion gear (3) with Installer 6448 (2) and a press (1).
8. Install new collapsible spacer (1) on pinion gear and install pinion in housing.
9. Install front pinion bearing on pinion shaft.
10. Install new pinion seal with Installer C-4076-B and Handle C-4735-1.
11. Install pinion flange with Installer C-3718.
12. Install bolts into two of the threaded holes in the flange 180° apart.
13. Position Holder 6719 against the flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
14. Install flange washer and a new nut on pinion and tighten pinion nut until there is zero end-play.
15. With a torque wrench (3) tighten the pinion nut to 285 Nm (210 ft. 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. Failure to follow these instructions will result in damage.
16. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure rotating torque frequently with an inch pound torque wrench (2) to avoid over crushing the collapsible spacer.
17. Check pinion rotating torque with an inch pound torque wrench. The pinion rotating torque should be:
^ Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.).
^ New Bearings: 2 to 5 Nm (15 to 35 inch lbs.).
18. Position exciter ring on differential case. With a brass drift slowly and evenly tap the exciter ring into position.
19. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
20. Invert the differential case in the vise.
21. Install new ring gear bolts (2) and alternately tighten to 102 Nm (75 ft. lbs.).
CAUTION: Never reuse the bolts that held the ring gear to the differential case. Failure to follow these instructions will result in fracture bolts can causing extensive damage.
22. Install differential in housing and verify gear mesh, backlash and contact pattern.
23. Install differential cover.