Ring and Pinion

GEAR-PINION/RING

REMOVAL

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

1. Mark companion flange and propeller shaft for installation reference.
2. Remove propeller shaft.
3. Remove axle shafts.
4. Remove differential from the differential housing.





5. Place differential case (1) 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 (2) with a soft hammer (3).





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





12. Remove pinion gear from the housing with a soft hammer (1).
13. Remove pinion seal with a pry tool or slide-hammer mounted screw.
14. Remove front pinion bearing and oil slinger if equipped.





15. Remove front pinion bearing cup with Remover C-4345 (1) and Handle C-4171 (2).





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





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





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





19. 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. 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 equivalent stick lubricant to outside surface of the pinion bearing cups.





2. Install rear pinion bearing cup with Installer C-4310 (1) and Handle C-4171 (2) and verify cup is seated.





3. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2) and verify cup is seated.
4. 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 C-4735-1(1).





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





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





8. Install a new collapsible spacer (1) on the pinion shaft.
9. Lubricate rear pinion bearing and install pinion gear into the housing.
10. Install companion flange with Installer C-3718 and Holder 6719.
11. Install bolts into two of the threaded holes in the companion flange 180° apart.





12. Position Holder 6719 (2) against the companion 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.
13. Install companion flange washer and a new nut on the pinion and tighten the nut until there is zero bearing end-play.
14. With a torque wrench (3) tighten the nut to 285 Nm (210 ft. lbs.).

CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the collapsible spacer.

15. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure pinion 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:
^ Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.).
^ New Bearings: 1.7 to 5 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 156 Nm (115 ft. lbs.).

CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction will damage will damage the bolts.

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.