Gear-Pinion/Ring/Tone Ring

GEAR-PINION/RING/TONE RING

REMOVAL

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

1. With vehicle in neutral, position on hoist.
2. Remove propeller shaft.
3. Remove axle shafts.
4. Remove differential from the differential housing.
5. Place differential case in a vise with soft metal jaw protectors.
6. Remove ring gear bolts from the differential case.





7. Drive ring gear (2) off the differential case (1) with a dead blow hammer (3).





8. Install bolts into two of the threaded holes in the companion flange 180° apart.
9. 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.
10. Use Holder 6719A to hold companion flange and remove the companion flange nut and washer.
11. Remove the companion flange (1) from the pinion with Puller C-452 (2).





12. Remove pinion gear from housing with a dead blow hammer (1).





13. Remove pinion seal with a seal pick.
14. Remove oil slinger if equipped and front pinion bearing.
15. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171(2).





16. Remove rear bearing cup from housing with Remover C-4307 (1) and Handle C-4171(2).





17. Remove collapsible preload spacer (1) from pinion shaft.





18. Remove rear pinion bearing from pinion shaft (4) with Puller/Press C-293-PA (1) and Adapters C-293-37 (3).





19. Remove pinion depth shims (1) from pinion shaft (2) and record shim thickness.

INSTALLATION

NOTE: The ring gear and pinion are serviced in a matched set. Do not replace one gear without replacing the 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-4310 (1) and Handle C-4171 (2).





3. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).





4. Install lubricate and install front pinion bearing into the housing.
5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B (3) and Handle (1) C-4735-1.





6. Install pinion depth shim (1) on the pinion shaft (2).





7. Install rear bearing (4) on the pinion (3) with Installer C-3095-A (2) and a press (1).





8. Install new collapsible spacer (1) on the pinion shaft.
9. Lubricate rear pinion bearing and install the pinion into the housing.





10. Install companion flange with Installer C-3718 and Holder 6719A.
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.
14. With a torque wrench (3) tighten the nut to 285 Nm (210 ft. lbs.).

NOTE: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.





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 (2). The pinion rotating torque should be: With Original Bearings: 1 to 2 Nm (10 to 20 inch lbs.). With 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 on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
19. Invert the differential case (4) in the vise.
20. Install new ring gear bolts (2) and alternately tighten to 157 Nm (115 ft. lbs.).

CAUTION: Never reuse ring gear bolts. The bolts can fracture causing extensive damage.

21. Install differential in housing and verify gear mesh, backlash and contact pattern.
22. Install axle shafts.
23. Install differential cover and fill with gear lubricant.
24. Install propeller shaft with reference marks aligned.