Gear, Ring And Pinion: Installation: Installation

WARNING: This page is about a different car, the 2012 RAM Pickup and 2012 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing Front Pinion Bearing Cup

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Install new front pinion bearing cup with Installer (special tool #8960, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 2: Installing Rear Pinion Bearing Cup
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Install new rear pinion bearing cup with Installer (special tool #8968, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 3: Installing Pinion Depth Shim
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Install pinion depth shim (1) on the pinion gear shaft (2).

Fig 4: Installing Rear Pinion Bearing
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Install rear pinion bearing (4) with Installer (special tool #D-389, Installer, Bearing) (1) and a press (1).

Fig 5: Installing Collapsible Spacer
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Install new collapsible spacer (1) on the pinion (2).
Lubricate pinion and bearings.

Fig 6: Pinion Gear Installer
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Install pinion into the housing (2) and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer (special tool #8981, Installer, Bearing Cup) (1).

Fig 7: Pinion Seal Installer
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Install new pinion seal with Installer (special tool #8896, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).

Fig 8: Flange Wrench
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Apply a light coat of teflon sealant to the pinion flange splines.
Hold pinion and lightly tap the pinion flange (2) onto the pinion, until a few threads are showing.
Install pinion flange washer and new pinion nut.
Hold pinion flange (2) with Flange Wrench (special tool #8979, Wrench, Pinion Flange) (1) and tighten pinion nut until pinion end play is eliminated.

Fig 9: Measuring Pinion Rotating Torque
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Rotate pinion several times to seat pinion bearings.
Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotate is achieved.
Pinion Torque To Rotate is:
- New Pinion Bearings: 1.7 - 2.8 N.m (15 - 25 in. lbs.)
- Original Pinion Bearings: 1.1 - 2.2 N.m (10 - 20 in. lbs.)
Rotate pinion several times then verify pinion rotating torque again.

Fig 10: Ring Gear, Differential Case & Bolts
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Position the ring gear (2) on differential case (4) and start two new ring gear bolts.
Install the rest of the new ring gear bolts and tighten them alternately to seat the ring gear.
Torque ring gear bolts to 237 N.m (175 ft. lbs.).

Fig 11: Installing Exciter Ring
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If exciter ring was removed, position differential assembly on differential Plug (special tool #8965, Installer, Differential Bearing) and place exciter ring (1) on the differential case.
Install the exciter ring on the differential case evenly with a hammer and brass punch (2). Drive the ring down until it is seated against the ring gear (2).
Install differential in housing.
Measure Total Torque To Rotate (TTTR) with an inch pound torque wrench.
Total Torque To Rotate is:
- New Bearings: 3.4 - 5.6 N.m (30 - 50 in. lbs.)
- Original Bearings: 2.8 - 5.1 N.m (25 - 45 in. lbs.)
  NOTE:
  If TTTR is to high, back off adjusters evenly on both sides slightly and check TTTR again. If TTTR is to low, tighten adjusters evenly on both sides slightly and check TTTR again.
Verify ring gear backlash and gear contact pattern.