Rear Axle - 210RII: 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

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Install selected pinion depth shim into housing.

Fig 2: Pinion Head Bearing Cup Installation
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Press pinion head bearing cup into housing using Tools C-4171 (1) and C-4310 (2).

Fig 3: Pinion Tail Bearing Cup Installation
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Press pinion tail bearing cup into housing using Tools C-4171 (1) and D-146 (2).

Fig 4: Pinion Head Bearing Installation
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Press new pinion head bearing (2) onto pinion shaft using Tool C-3095-A (1).

Fig 5: Collapsible Spacer and Washers
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Install washers (2) and new collapsible spacer (1) to pinion shaft.

Fig 6: Support Pinion Head and Carrier
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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
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Using Tool C-3095-A (1), press on new pinion tail bearing (2).

Fig 8: Pinion Seal
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1 - PINION SEAL

2 - DIFFERENTIAL HOUSING
Install new pinion seal (1) into position.

Fig 9: Pinion Seal Installation
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Press pinion seal into housing using Tool 9231A (1).

Fig 10: Pinion Flange Installation
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Lightly lubricate pinion flange seal with axle lubricant for flange installation.
Align index marks and press pinion flange (2) on using Tool C-3095-A (1).

Fig 11: Torquing Pinion Flange Nut
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Install new pinion flange nut by hand.
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 12: Measuring Rotating Torque
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Rotate pinion flange to ensure bearing is properly seated.
Measure pinion rotating torque using suitable torque wrench (1). Pinion rotating torque should be 215-245 N. cm (19-22 in. lbs.).
If pinion rotating torque exceeds the specified range, the pinion shaft must be removed and the crush sleeve replaced.

Fig 13: Torquing Pinion Flange Nut
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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 14: Staking Pinion Flange Nut
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Stake pinion flange nut (1) using hammer and suitable punch.

Fig 15: Ring Gear Bolts
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Install ring gear to differential case. Loosely install new ring-gear-to-differential case bolts.
Torque all ring gear-to-case bolts to 85 N.m (64 ft. lbs.)

Fig 16: Removing/Installing Differential
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Install differential and reassemble axle assembly. (Refer to DIFFERENTIAL & DRIVELINE/REAR AXLE - 210MM/DIFFERENTIAL - INSTALLATION)