Gear-Pinion/Ring/Tone Ring
GEAR-PINION/RING/TONE RINGREMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear.
1. Remove differential from the axle housing.
2. Mark the companion flange and propeller shaft for installation alignment.
3. Disconnect propeller shaft from the companion flange and tie propeller shaft to underbody
4. Place differential case (1) in a suitable vise with soft metal jaw protectors.
5. Remove ring gear (2) bolts from the differential case.
6. Drive ring gear off the differential case with a soft hammer (3).
7. Install bolts into two of the threaded holes in the companion flange 180° apart.
8. Position Holder 6719A against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719A is held to the flange.
9. Hold companion flange with Holder 6719A and remove companion flange nut and washer.
10. Remove the companion flange (1) with Puller C-452 (2).
11. Remove pinion from housing with a soft hammer (1).
12. Remove pinion seal with a pry tool or slide-hammer mounted screw.
13. Remove oil slinger if equipped and front pinion bearing.
14. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171 (2).
15. Remove rear bearing cup from housing with Remover C-4307 (1) and Handle C-4171 (2).
16. Remove collapsible preload spacer (1).
17. Remove rear bearing from pinion (4) with Puller/ Press C-293-PA (1) and Adapters C-293-47 (3).
18. Remove pinion depth shim (1) from the pinion shaft (2) and record shim thickness.
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, Refer to Adjustments for Pinion Gear Depth Setting.
1. Apply Mopar Door Ease or equivalent stick lubricant to outside surface of pinion bearing cups.
2. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171(l).
3. Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171(2).
4. Lubricate and 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 pinion depth shim (1) on the pinion shaft (2).
7. Install rear pinion bearing (4) and slinger if equipped, on the pinion (3) with Installer 6448A (2) and a press (1).
8. Install a new collapsible spacer (1) on the pinion gear shaft.
9. Lubricate rear pinion bearing (2) and install pinion into the housing.
10. Install companion flange with Installer C-3718 and Holder 6719A (2).
11. Install bolts into two of the threaded holes in the companion flange 180° apart.
12. Position Holder 6719A(2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719A is held to the flange.
13. Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play.
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.
14. With a torque wrench (3) tighten the pinion nut to 285 Nm (210 ft. lbs.).
15. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.
16. 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: 1.7 to 4 Nm (15 to 35 inch lbs.)
17. Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position.
18. Position ring gear (3) on the differential case (4) and start two ring gear bolts (2). This will provide case-to-ring gear bolt hole alignment.
19. Invert the differential case in the vise.
20. Install new ring gear bolts and alternately tighten to 102 Nm (75 ft. lbs.).
CAUTION: Do not reuse ring gear bolts. Failure to follow these instructions will result in bolts fracturing causing damage.
21. Install differential in housing and verify gear mesh, backlash and contact pattern.
22. Install differential cover and fill with gear lubricant.
23. Install propeller shaft with reference marks aligned.