Gear - Pinion/Ring

FRONT AXLE - 181FBI

GEAR - PINION/RING

REMOVAL

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

1. Remove differential from axle housing.

Fig. 62 RING GEAR:

2. Secure differential case in a vise with soft metal jaw (Fig. 62).
3. Remove ring gear bolts from the differential case.
4. Drive ring gear off the differential case with a dead-blow hammer (Fig. 62).

Fig. 63 YOKE SPANNER WRENCH:

5. Hold yoke with Spanner Wrench 6958 and remove the pinion nut and washer (Fig. 63).

Fig. 64 PINION YOKE:

6. Remove pinion yoke with Remover C-452 and Flange Wrench C-3281 (Fig. 64).

Fig. 65 PINION GEAR:

7. Remove pinion and collapsible spacer from the housing (Fig. 65).

Fig. 66 FRONT BEARING CUP:

8. Remove front pinion bearing cup, bearing, oil slinger and pinion seal with Remover C-4345 and Handle C-4171 (Fig. 66).

Fig. 67 REAR BEARING CUP:

9. Remove rear pinion bearing cup from the housing (Fig. 67) with Remover D-149 and Handle C-4171.

Fig. 68 COLLAPSIBLE SPACER:

10. Remove collapsible spacer from pinion shaft (Fig. 68).

Fig. 69 REAR PINION BEARING:

11. Remove rear pinion bearing with Puller/Press C-293-PA and Adapters C-293-39 (Fig. 69).
12. Remove pinion depth shim/oil slinger from the pinion shaft and record thickness.

INSTALLATION

NOTE: A pinion depth shim/oil slinger is placed between the rear pinion bearing cone and the pinion head to achieve proper ring gear and pinion mesh. If ring gear and pinion are reused, the pinion depth shim/oil slinger should not require replacement. Refer to Adjustment (Pinion Gear Depth) to select the proper thickness shim/oil slinger if ring and pinion gears are replaced.

Fig. 70 REAR PINION BEARING CUP:

1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the pinion bearing cups. Install rear bearing cup with Installer D-146 and Driver Handle C-4171 (Fig. 70) and verify cup is seated.

Fig. 71 FRONT PINION BEARING CUP:

2. Install front bearing cup with Installer D-130 and Handle C-4171 (Fig. 71) and verify cup is seated.
3. Install front pinion bearing, and oil slinger.

Fig. 72 PINION SEAL INSTALLER:

4. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with an appropriate installer (Fig. 72).

Fig. 73 REAR PINION BEARING:

5. Install rear pinion depth shim/oil slinger and bearing on the pinion shaft with Installer W-262 and a press (Fig. 73).

Fig. 74 COLLAPSIBLE PRELOAD SPACER:

6. Install new collapsible spacer on pinion shaft and install pinion into the housing (Fig. 74).

Fig. 75 PINION YOKE INSTALLER:

7. Install yoke with Installer W-162-B, Cup 8109 and Spanner Wrench 6958 (Fig. 75).
8. Install pinion washer and a new nut onto the pinion. Tighten the nut to 216 Nm (160 ft. lbs.).

CAUTION: Never loosen the pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to heed caution may result in damage.

Fig. 76 YOKE SPANNER WRENCH:

Fig. 77 PINION ROTATION TORQUE:

9. Using Spanner Wrench 6958 and torque wrench set at 678 Nm (500 ft. lbs.) (Fig. 76). Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 77).

CAUTION: If more than 678 Nm (500 ft. lbs.) torque is required to crush the collapsible spacer, the spacer is defective and must be replaced. Failure to heed caution may result in damage.

10. Check bearing rotating torque with an inch pound torque wrench (Fig. 77). The torque necessary to rotate the pinion should be:
- Original Bearings: 1.13 to 2.26 Nm (10 to 20 inch lbs.).
- New Bearings: 1.7 to 3.4 Nm (15 to 30 inch lbs.).
11. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.

Fig. 78 RING GEAR BOLT:

12. Invert the differential case in the vise and install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.) (Fig. 78).

CAUTION: Never reuse ring gear bolts. Failure to heed caution may result in damage.
13. Install differential and verify differential bearing preload, gear mesh and contact pattern.