B. Replace Front Axle Ring and Pinion
1 With a drain pan under the differential housing cover, remove the cover and drain the lubricant from the axle housing.2. Remove both front wheels.
3. Remove the front hub bearings and axle shafts as an assembly using the following procedure:
a. Remove both front brake caliper adapter bolts and then remove the caliper and adapter as an assembly (Figure 28).
CAUTION:
Do not allow the brake caliper/adapter assembly to hang from the brake hydraulic flex hose.
b. Remove and save both front brake rotors.
c. For vehicles equipped with an Antilock Brake System (ABS), remove both ABS wheel speed sensor (Figure 29).
d. Remove the four hub bearing retaining bolts from the back of both steering knuckles.
e. Remove hub bearings and axle shafts from the steering knuckles as an assembly (Figure 30).
4. Using Tie Rod Puller 8677, disconnect the left side tie rod end from the steering knuckle (Figure 31).
5. Tie strap the steering linkage to the sway bar (Figure 32).
NOTE:
Moving the steering linkage will give access required to remove the differential case and ring gear.
6. Mark the pinion flange and propeller shaft for installation alignment.
7. Disconnect the propeller shaft at the axle flange and support the propeller shaft with a bungee cord.
8. Remove the differential bearing adjuster lock bolts and adjuster locks (Figure 33).
9. Mark the differential bearing caps left and right for installation reference.
10. Loosen the differential bearing cap bolts (Figure 33).
11. Using a hammer and punch, loosen both of the differential bearing adjusters (Figure 33).
12. Remove the differential bearing caps and remove the differential case from the axle housing.
13. Mark one of the differential bearing cups for installation reference (Figure 34).
14. Replace the ring gear using the following procedure:
a. Place the differential case in a vise with soft metal jaw protectors.
b. Remove the 12 bolts holding ring gear to the differential case.
NOTE:
The ring gear bolts have left-handed threads.
c. Partially install four of the old ring gear bolts back into the differential case 90 degrees apart (Figure 35).
d. Drive the old ring gear from the differential case by alternately hitting the four bolt heads to drive the ring gear off the differential case (Figure 35).
e. Clean the new ring gear and mounting surface on the differential case.
f. Position the new ring gear on differential case and start two new ring gear bolts.
g. Install the remaining new ring gear bolts and tighten them alternately to seat the ring gear. Tighten the ring gear bolts to 103 ft. lbs. (140 N.m).
h. Set differential case assembly aside for later installation.
15. Remove the pinion gear from the differential housing using the following procedure:
a. Hold pinion flange with Flange Wrench 8979 and remove pinion flange nut (Figure 36).
b. Remove Flange Wrench 8979 from the pinion flange.
c. Using Pinion Flange Puller 8992, remove pinion flange from the pinion (Figure 37).
d. Remove the pinion flange puller from the pinion flange.
e. Remove the pinion gear from the axle housing with pinion Driver 8976 and a hammer (Figure 38).
NOTE:
Thread the pinion driver onto the pinion shaft until it bottoms out on the pinion shaft.
16. Remove the pinion seal with a slide hammer or pry bar.
17. Remove and discard the front pinion bearing.
18. Using a punch and hammer, remove the front pinion bearing cup from the axle housing and discard.
19. Using a punch and hammer, remove the rear pinion bearing cup from the housing and discard.
20. Clean the inside of the differential housing using brake cleaner spray and compressed air.
21. Using Installer D-146 and Handle C-4171, install a new front pinion bearing cup into the differential housing (Figure 39).
22. Using Installer 8886 and Driver Handle C-4171 and C4171-2, install a new rear pinion bearing cup into the differential housing (Figure 40).
23. Determine the correct pinion depth for the new drive pinion using the following procedure:
NOTE:
Use Pinion Depth Gauge Set 6730 and Dial Indicator C-3339A.
a. Assemble Pinion Height Block 6739, Pinion Block 8878 and rear pinion bearing onto Screw 6741 (Figure 41).
b. Insert assembled pinion block, pinion height block, rear bearing and screw into the housing through pinion bearing cups (Figure 41).
NOTE:
Be sure to lubricate the front and rear pinion bearings with gear oil before installing.
c. Install front pinion bearing and Cone-nut 6740 onto the screw. Tighten cone-nut until torque to rotate the screw is 15-20 in. lbs. (1.7-2.26 N.m).
d. Place Arbor Discs 8289 on Arbor D-115-3 in position in the housing side bearing cradles (Figure 42).
e. Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts to 63 ft. lbs. (85 N.m) (Figure 42).
NOTE:
Arbor should rotate freely in the arbor discs.
f. Assemble Dial Indicator C-3339A into Scooter Block D-115-2 and secure the set screw (Figure 43).
g. Position the scooter block/dial indicator flush on the pinion height block. Hold the scooter block and zero the dial indicator (Figure 44).
h. Slowly slide the scooter block up the pinion height block over the arbor. Move the scooter block until the dial indicator crests the arbor, then record the highest reading (Figure 44).
i. Select a shim equal to the dial indicator reading.
j. Remove the pinion depth measuring tools.
24. Install the shim selected in Step 23i, between the rear pinion bearing and the new pinion gear head (Figure 45).
25. Install the rear pinion bearing onto the pinion with Installer C-3095A and a hydraulic press.
26. Install a new crush sleeve on the pinion.
27. Lubricate both pinion bearings.
28. Install the pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8982 (Figure 46).
29. Apply a light coat of grease to the lip of the pinion seal and then install the new pinion seal with Installer 8882 and Drive Handle C-4171 (Figure 47).
30. Clean out all of the old sealant from the splines in the pinion flange.
31. Apply a light coat of teflon sealant to the pinion flange splines.
32. Hold pinion and lightly tap the pinion flange onto the pinion, until a few threads are showing.
33. Install the pinion flange washer and new pinion nut.
34. Hold the pinion flange with Flange Wrench 8979 and tighten pinion nut until the pinion end play is eliminated.
35. Rotate pinion several times to seat pinion bearings.
36. Measure pinion torque to rotate with an inch pound torque wrench. Tighten pinion nut in 5 ft. lbs. (6.8 N.m) increments until pinion torque to rotate is achieved. Pinion torque to rotate for new pinion bearings is 15 - 25 in. lbs. (1.7 - 2.8 N.m).
37. Rotate the pinion several times and then verify the pinion rotating torque again.
38. Apply gear lube to the bearing cup races and the differential case bearing cones. Then place the new differential case bearing cups onto the differential case bearing cones.
39. Install the differential case assembly with bearing cups into the differential housing.
NOTE:
Be sure that the bearing cup that was marked in Step 13 is installed on the marked bearing.
40. Install the differential case retaining caps into position and snug the retaining bolts (Figure 48).
41. Slide differential case toward the pinion gear until the gears make contact/zero backlash.
NOTE:
If zero backlash cannot be obtained, turn the ring gear side adjuster until zero backlash is obtained.
42. While holding the differential case toward the pinion gear, turn bearing adjusters with Adjuster Wrench 8883A until the adjuster makes contact with the differential bearings/cups (Figure 48).
43. Back off the ring gear bolt side bearing adjuster four holes, to obtain initial ring gear backlash (Figure 48).
44. Install the ring gear bolt side bearing adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
45. Tighten the ring gear side bearing adjuster firmly against the differential case bearing cup.
46. Rotate the pinion several times to seat the differential bearings.
47. Loosen the ring gear side bearing adjuster until it is no longer in contact with the bearing cup, then tighten it until it makes contact (Figure 48).
48. Tighten the ring gear side bearing adjuster an additional six adjuster holes
49. Tighten the bearing cap bolts to 63 ft. lbs. (85 N.m).
50. Install the ring gear side bearing adjuster lock and bolt.
51. Tighten adjuster lock bolts to 18 ft. lbs. (25 N.m).
52. Again, rotate the pinion several times to seat the differential bearings.
53. Measure the ring gear backlash with Dial Indicator C-3339A and Pilot Stud L-4438 at eight points around the drive side of the ring gear (Figure 49). The backlash should be 0.003-0.010 in. (0.08-0.25 mm) with a preferred backlash of 0.005-0.007 in. (0.13-0.18 mm).
NOTE:
Backlash measurement should not vary more than 0.002 in (0.05 mm) between measuring points. If measurement does vary, inspect the gears for burrs, the differential case flange and ring gear mounting.
54. Measure the total torque to rotate at the pinion nut with an inch pound torque wrench. The total torque to rotate is 30 - 50 in. lbs. (3.4 - 5.6 N.m).
NOTE:
If total torque to rotate is too high, back off adjusters evenly on both sides slightly and recheck. If total torque to rotate is too low, tighten adjusters evenly on both sides slightly and recheck.
55. Check the gear tooth contact pattern using the following procedure:
a. Wipe clean each tooth of the ring gear.
b. Apply gear marking compound (P/N 04883065) to all of the ring gear teeth (Figure 50).
c. Create an additional 10 ft. lbs. (14 N.m) pinion rotating torque.
d. Rotate the pinion/pinion yoke four full revolutions in each direction.
e. Read gear tooth contact pattern:
> The gear contact pattern is correct. Backlash and pinion depth is correct (Figure 51).
> The ring gear is too far away from pinion gear, coast side toe (1) and drive side heel (2). Decrease backlash, by moving the ring closer to the pinion gear using the adjusters (Figure 52).
> The ring gear is too close to the pinion gear, drive side toe (1) and coast side heel (2). Increase backlash, by moving the ring away from the pinion gear using the adjusters (Figure 53).
> The ring gear is too far away from pinion gear, drive side heel (1) and coast side heel (2). Decrease the backlash, by moving the ring closer to the pinion gear using the adjusters (Figure 54).
> The ring gear too close to the pinion gear, drive side toe (1) and coast side toe (2). Increase the backlash, by moving the ring away from the pinion gear using the adjusters (Figure 55).
> The pinion gear is set too low. Increase the pinion gear height, by increasing the pinion depth shim thickness (Figure 56).
> The pinion gear is set too high. Decrease the pinion depth, by decreasing the pinion depth shim thickness (Figure 57).
56. Install the hub bearing/axle shaft assemblies using the following procedure:
a. Install the axle shaft and bearing hub assembly through the steering knuckle and into the differential side gears (Figure 30).
b. Install the hub bearing retaining bolts and tighten them to 150 ft. lbs. (202 N.m).
c. Install the ABS wheel speed sensor (Figure 29).
d. Install the brake rotor and caliper/adapter assembly. Tighten the caliper adapter bolts to 250 ft. lbs. (339 N.m).
e. Repeat steps 54a through 54d on the other front wheel.
57. Clean the front axle differential cover.
58. Install front axle cover gasket and bolts. Tighten the bolts to 30 ft. lbs. (40 N.m).
59. Align the marks made on the propeller shaft, apply thread locker to the bolt threads and install. Tighten the bolts to 21 ft. lbs. (28 N.m).
60. Connect the left tie rod end to the steering knuckle. Tighten the tie rod nut to 40 ft. lbs. (54 N.m) then an additional 90 degrees.
61. Install the wheel and tire assemblies. Tighten lug nuts to 140 ft. lbs. (190 N.m).
62. Remove the front axle fill plug and fill axle with Mopar Synthetic Gear Lubricant SAE 75W-90 (P/N 05102232AA) until the axle lube is 1/4 inch below the bottom of the fill plug hole. The gear lubricant capacity on the front axle differential is 2.3 quarts (2.2 liters).
63. Install the front axle fill plug.
64. Lower the vehicle from the hoist and continue with Section C. Program Tire Size and Axle Ratio.