Pinion Depth Measurement

Fig 1: Measuring Pinion Depth With Gauge Tools

Courtesy of CHRYSLER GROUP, LLC

Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with (special tool #C-3339A, Set, Dial Indicator) (1).

1. Assemble (special tool #6739, Block, Height) (3), (special tool #8542, Gauge, Pinion Height) (6) and rear pinion bearing onto (special tool #6741, Screw) (5).
   Fig 2: Identifying Pinion Block & Height Block

   Courtesy of CHRYSLER GROUP, LLC
2. Insert pinion block (1), pinion height block (2), rear bearing, and screw into the housing through pinion bearing cups.
3. Install a new front pinion bearing and

   (special tool #6740, Cone)

   onto the screw. Tighten cone-nut until Torque To Rotate of the screw is 2.5 N.m (22 in. lbs.).

   NOTE:

   Do not reuse pinion bearings.

   Fig 3: Identifying Pinion Depth Tools

   Courtesy of CHRYSLER GROUP, LLC
4. Place (special tool #8541A, Set, Arbor Disc) (1) on (special tool #D-115-3, Arbor) (3) in position in the housing side bearing cradles. Install differential bearing caps on arbor discs and tighten cap bolts to 41 N.m (30 ft. lbs.).
   Fig 4: Identifying Pinion Gear Depth Measurement

   Courtesy of CHRYSLER GROUP, LLC
5. Assemble (special tool #C-3339A, Set, Dial Indicator) (3) into (special tool #D-115-2A, Block, Scooter) (2) and secure set screw.
6. Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion height block. Hold scooter block in place and zero the dial indicator. Tighten dial indicator face lock screw.
7. Slide the dial indicator probe across the gap between the pinion height block and the arbor bar (1) with the scooter block against the pinion height block. Continue moving the dial probe to the crest of the arbor bar and record the highest reading.
   NOTE:

   Subtracting 0.072 mm (0.003) from the over all calculation is to compensate for the bearing growth factor.

8. Select a shim equal to the dial indicator reading plus or minus the pinion depth variance calculated earlier, then subtract 0.072 mm (0.003 in.) from the over all calculations. If the calculated pinion depth variance recorded earlier is positive (+), add  the calculated number from the dial indicator reading. If the calculated pinion depth variance recorded earlier is negative (-), subtract  the calculated number to the dial indicator reading.
   NOTE:

   Shim thickness = Dial indicator reading plus (+) the pinion depth variance minus (-) the bearing growth factor.

   Example 1: Shim thickness = 1.90 mm (dial indicator reading) plus (+) +0.010 mm (a positive pinion depth variance) minus (-) 0.072 mm (bearing growth factor) = 1.838 mm.

   Example 2: Shim thickness = 1.90 mm (dial indicator reading) plus (+) - 0.010 mm (a negative pinion depth variance) minus (-) 0.072 mm (bearing growth factor) = 1.818 mm.

9. Remove old pinion bearings, bearing cups and seal from carrier

   Refer to GEAR, RING AND PINION, REMOVAL .

   and install a new bearing with selected shim as close as possible to the calculated number behind the bearing cup.

   NOTE:

   The pinion bearings, bearing cups and pinion seal must be replaced when making shim adjustment changes

   Refer to GEAR, RING AND PINION, INSTALLATION .

   Fig 5: Identifying Collapsible Spacer

   Courtesy of CHRYSLER GROUP, LLC
10. Install a new  collapsible spacer (1) on the pinion shaft.
11. Apply Mopar® Thread Sealant to splines of the pinion shaft.
12. Install companion flange with (special tool #C-3718, Installer, Flange) and (special tool #6719A, Holder, Yoke).
    Fig 6: Tightening Pinion Nut With Torque Wrench

    Courtesy of CHRYSLER GROUP, LLC
13. Install bolts into two of the threaded holes in the companion flange 180° apart.
14. Position (special tool #6719A, Holder, Yoke) (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the (special tool #6719A, Holder, Yoke) is held to the flange.
15. Install new  pinion nut.
16. Hold companion flange with (special tool #6719A, Holder, Yoke) (2) and tighten pinion nut with a torque wrench (3) to 285 N.m (210 ft. lbs.).
    NOTE:

    Do not exceed minimum torque 285 N.m (210 ft. lbs.) at this point.

    Fig 7: Checking Pinion Rotating Torque

    Courtesy of CHRYSLER GROUP, LLC
17. Rotate pinion several times to seat pinion bearings.
18. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Measure pinion rotating torque frequently to avoid over-crushing the collapsible spacer.

    Pinion Torque To Rotate is:

    • Pinion torque to rotate with New Bearings:  1.9 - 2.5 N.m (17 - 22 in. lbs.)
      NOTE:

      If pinion torque to rotate is low, tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotate is achieved.