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Rear Axle - 198RII: Gear-Pinion/Ring: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Shim Removal/Installation
GC0014253Courtesy of DAIMLERCHRYSLER CORP.
  1. Install selected pinion depth shim (1) into housing.
    Fig 2: Pinion Head Bearing Cup Installation
    GC0014246Courtesy of DAIMLERCHRYSLER CORP.
  2. Press pinion head bearing cup into housing using Tools C-4171 (1) and C-4310 (2).
    Fig 3: Pinion Tail Bearing Cup Installation
    GC0014247Courtesy of DAIMLERCHRYSLER CORP.
  3. Press pinion tail bearing cup into housing using Tools C-4171 (1) and D-146 (2).
    Fig 4: Pinion Head Bearing Installation
    GC0014333Courtesy of DAIMLERCHRYSLER CORP.
  4. Press new  pinion head bearing (2) onto pinion shaft using Tool C-3095-A (1).
    Fig 5: Collapsible Spacer and Washers
    GC0014329Courtesy of DAIMLERCHRYSLER CORP.
  5. Install washers (2) and new  collapsible spacer (1) to pinion shaft.
    Fig 6: Support Pinion Head and Carrier
    GC0014334Courtesy of DAIMLERCHRYSLER CORP.
  6. Install pinion shaft (1) into housing and support on press table atop Tool 8255 (2). Ensure pinion gear face is centered atop Tool 8255. 
    Fig 7: Pinion Tail Bearing Installation
    GC0014335Courtesy of DAIMLERCHRYSLER CORP.
  7. Using Tool C-3095-A (1), press on new  pinion tail bearing (2).
    Fig 8: Pinion Seal Installation
    GC0014336Courtesy of DAIMLERCHRYSLER CORP.
  8. Install new pinion seal into position.
  9. Press pinion seal into housing using Tool 9231A (1).
    Fig 9: Pinion Flange Installation
    GC0014337Courtesy of DAIMLERCHRYSLER CORP.
  10. Lightly lubricate pinion flange seal with axle lubricant for flange installation.
  11. Align index marks and press pinion flange (2) on using Tool C-3095-A (1).
    Fig 10: Torquing Pinion Flange Nut
    GC0014338Courtesy of DAIMLERCHRYSLER CORP.
  12. Install new pinion flange nut by hand.
  13. Hold pinion flange with Tool C-3281 (1). Using a deep 41 mm socket, tighten pinion flange nut to an initial torque of 203 N.m (150 ft. lbs.).
    Fig 11: Measuring Rotating Torque
    GC0014299Courtesy of DAIMLERCHRYSLER CORP.
  14. Rotate pinion flange to ensure bearing is properly seated.
  15. Measure pinion rotating torque using suitable torque wrench (1). Pinion rotating torque should be 215-245 N. cm (19-22 in. lbs.). 
  16. If pinion rotating torque exceeds the specified range, the pinion shaft must be removed and the crush sleeve replaced.
    Fig 12: Torquing Pinion Flange Nut
    GC0014338Courtesy of DAIMLERCHRYSLER CORP.
  17. If pinion rotating torque is below the specified range, increase nut torque by 7 N.m (5 ft. lbs.) increments and recheck turning torque until rotating torque is within range.
    Fig 13: Staking Pinion Flange Nut
    GC0014302Courtesy of DAIMLERCHRYSLER CORP.
  18. Stake pinion flange nut (1) using hammer and suitable punch.
    Fig 14: Ring Gear Bolts
    GC0014310Courtesy of DAIMLERCHRYSLER CORP.
  19. Install ring gear to differential case. Loosely install new  ring-gear-to-differential case bolts.
  20. Torque all ring gear-to-case bolts to 85 N.m (64 ft. lbs.)
    Fig 15: Removing/Installing Differential
    GC0014307Courtesy of DAIMLERCHRYSLER CORP.
  21. Install differential and reassemble axle assembly. (Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 198MM/DIFFERENTIAL - INSTALLATION) 
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