Pinion Gear: Service and Repair

PINION GEAR REMOVAL AND INSTALLATION


NOTE: The ring and pinion gears are serviced as a matched set. Do not replace the pinion gear without replacing the ring gear.

REMOVAL
1. Remove differential assembly from axle housing.
2. Mark pinion yoke and propeller shaft for installation alignment.
3. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody.
4. Using Holder 6958, or equivalent to hold yoke, remove the pinion nut and washer.





5. Using Remover C-452 and Holder C-3281, or equivalents, remove the pinion yoke from pinion shaft.





6. Remove the pinion gear and preload shims from housing. Catch the pinion with your hand to prevent it from falling and being damaged.





7. Remove the front pinion bearing cup, bearing, oil slinger, if equipped, and pinion seal with Remover D-147 and Handle C-4171, or equivalents.





8. Remove the rear pinion bearing cup from axle housing. Use Remover D-149 and Handle C-4171, or equivalents.
9. Remove the depth shims from rear pinion bearing cup bore in axle housing. Record the thickness of the depth shims.

NOTE: The pinion depth shims can be very thin. Verify that all shims have been removed before proceeding.





10. Remove the rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-39, or equivalents. Place 4 adapter blocks so they do not damage the bearing cage.

NOTE: Pinion depth shims are placed between the rear pinion bearing cup and axle housing to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. Refer to Pinion Gear Depth to select the proper thickness shim before installing pinion gear.

INSTALLATION
1. Place proper thickness depth shim in rear pinion bearing cup bore in the axle housing.





2. Apply Mopar (R) Door Ease, or equivalent, stick lubricant to outside surface of rear pinion bearing cup. Install the bearing cup with Installer D-146 and Handle C-4171, or equivalents. Verify cup is correctly seated.





3. Apply Mopar (R) Door Ease, or equivalent, stick lubricant to outside surface of front pinion bearing cup. Install the bearing cup with Installer D-144 and Handle C-4171, or equivalents.
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-3972-A and Handle C-4171, or equivalents.





6. Install the rear pinion bearing and oil slinger, if equipped, on the pinion gear with Installer W-262, or equivalent and a shop press.





7. Install pinion bearing preload shims onto the pinion gear.
8. Install pinion gear in housing.





9. Install yoke with Installer W-162-B, Cup 8109, and Holder 6958, or equivalents.
10. Install the pinion washer and a new nut on the pinion gear. Tighten the nut to 217 Nm (160 ft. lbs.).





11. Check bearing preload torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be:
^ Original Bearings: 1 to 3 Nm (10 to 20 inch lbs.).
^ New Bearings: 2 to 5 Nm (15 to 35 inch lbs.).
12. If rotating torque is above the desired amount, remove the pinion yoke and increase the preload shim pack thickness. Increasing the shim pack thickness 0.025 mm (0.001 inch) will decrease the rotating torque approximately 0.9 Nm (8 inch lbs.).
13. Tighten pinion shaft nut in 6.8 Nm (60 inch lbs.) increments until the maximum tightening or desired rotating torque is reached.
14. If the maximum tightening torque is reached prior to achieving the desired rotating torque, remove the pinion yoke and decrease the thickness of the preload shim pack. Decreasing the shim pack thickness 0.025 mm (0.001 inch) will increase the rotating torque approximately 0.9 Nm (8 inch lbs.).
15. Install differential assembly.