Differential Tru LOK

FRONT AXLE - 216FBI

GEAR - PINION/RING

REMOVAL

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

1. Remove differential from housing.
2. Secure differential case in a vise with soft metal jaw.
3. Remove ring gear bolts from the differential case.

Fig. 69 RING GEAR REMOVAL:

4. Drive ring gear off the differential case with a dead-blow hammer (Fig. 69).
5. Hold yoke with Holder 6719A and remove pinion nut and washer.

Fig. 70 PINION YOKE REMOVAL:

6. Remove pinion yoke from the pinion shaft with Puller C-452 and Flange Wrench C-3281 (Fig. 70).

Fig. 71 REMOVE PINION GEAR:

7. Remove pinion gear from housing (Fig. 71).
8. Remove pinion seal with a pry bar or slide hammer mounted screw.

Fig. 72 FRONT BEARING CUP REMOVAL:

9. Remove front pinion bearing cup with Remover D-147 and Handle C-4171 (Fig. 72). Remove pinion preload shims from cup bore.

Fig. 73 REAR BEARING CUP REMOVAL:

10. Remove rear bearing cup (Fig. 73) with Remover D-148 and Handle C-4171.

Fig. 74 REAR BEARING REMOVAL:

11. Remove rear pinion bearing with Puller C-293-PA and Adapters C-293-39 (Fig. 74).
12. Remove pinion depth shim/oil slinger from pinion shaft and record thickness.

INSTALLATION

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If ring and pinion gears are reused, the original pinion depth shim can be used. Refer to Adjustments (Pinion Gear Depth) to select the proper shim thickness if ring and pinion gears are replaced.

1. Apply Mopar Door Ease stick or equivalent lubricant to outside surface of bearing cups.

Fig. 75 REAR PINION BEARING CUP:

2. Install rear pinion bearing cup with Installer D-146 and Handle C-4171 (Fig. 75).

Fig. 76 PINION PRELOAD SHIMS:

3. Install pinion preload shims in front pinion cup housing bore (Fig. 76)

Fig. 77 FRONT PINION BEARING CUP INSTALLER:

4. Install front pinion bearing cup with Installer D-145 and Handle C-4171 (Fig. 77).
5. Install pinion front bearing, oil slinger. Apply a light coating of gear lubricant on the lip of pinion seal.

Fig. 78 PINION SEAL INSTALLER:

6. Install pinion seal with an appropriate installer (Fig. 78).
7. Install proper thickness depth shim on the pinion gear.

Fig. 79 REAR PINION BEARING:

8. Install rear bearing and oil slinger, if equipped on pinion gear with Installer W-262 (Fig. 79).
9. Install pinion gear in housing.

Fig. 80 PINION YOKE INSTALLER:

10. Install yoke with Installer W-162-D and Yoke Holder 6719A (Fig. 80).

Fig. 81 TIGHTENING PINION NUT:

11. Install yoke washer and a new nut on the pinion gear. Tighten the nut to specification (Fig. 81).

Fig. 82 PINION ROTATION TORQUE:

12. Check bearing preload torque with an inch pound torque wrench (Fig. 82). The torque to rotate the pinion gear should be:
- Original Bearings: 1 to 2 Nm (10 to 20 inch lbs.).
- New Bearings: 2.3 to 4.5 Nm (20 to 40 inch lbs.).

NOTE: Removing a pinion preload shim will increase the pinion torque to rotate. Adding a pinion preload shim will decrease the pinion torque to rotate.

13. Invert differential case in a vise and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.

Fig. 83 RING GEAR INSTALLATION:

14. Install new ring gear bolts and alternately tighten to 136 Nm (100 ft. lbs.). (Fig. 83).

CAUTION: Never reuse the ring gear bolts. Failure to heed caution may result in damage.

15. Install differential in axle housing and verify gear mesh and contact pattern. Refer to Adjustments (Gear Contact Pattern).