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Home >> Dodge and Ram >> 2003 >> Durango Base, 5.9 Z, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 33 (Front Axle - C205F) >> Pinion Gear/Ring Gear/Tone Ring >> Installation

Pinion Gear/Ring Gear/Tone Ring: Installation

WARNING: This page is about a different car, the 2004 Dodge Dakota and 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting.
  1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the bearing cups.
  2. Install rear pinion bearing cup with Installer D-145 and Driver Handle C-4171 (Fig 1 ) and verify cup is seated.
    Fig 1: Installing Rear Pinion Bearing Cup
    G02656115Courtesy of DAIMLERCHRYSLER CORP.
  3. Install front pinion bearing cup with Installer D-129 and Handle C-4171 (Fig 2 ) and verify cup is seated.
    Fig 2: Installing Front Pinion Bearing Cup
    G02656116Courtesy of DAIMLERCHRYSLER CORP.
  4. Install pinion front bearing and oil slinger if equipped.
  5. Apply a light coating of gear lubricant on the lip of pinion seal.
  6. Install pinion seal with Installer C-3972-A and Handle C-4171 (Fig 3 ).
    Fig 3: Installing Pinion Seal
    G02656117Courtesy of DAIMLERCHRYSLER CORP.
  7. Place the proper thickness depth shim (Fig 4 ) on the pinion shaft.
    Fig 4: Installing Pinion Depth Shim
    G02656118Courtesy of DAIMLERCHRYSLER CORP.
  8. Install rear bearing and slinger if equipped, onto the pinion shaft with Installer 6448 (Fig 5 )and a press.
    9. Fig 5: Installing Rear Pinion Bearing
    G02656119Courtesy of DAIMLERCHRYSLER CORP.
    Fig 6: Installing Collapsible Spacer
    G02656120Courtesy of DAIMLERCHRYSLER CORP.
  9. Install new  collapsible preload spacer onto the pinion shaft (Fig 6 ).
  10. Install the pinion gear in the housing.
  11. Install the companion flange with Installer C-3718 and Holder 6719.
  12. Install new  pinion nut and tighten to 271 N-m (200 ft. lbs.) (Fig 7 ).
  13. Using Holder 6719 and a torque wrench set at 474 N-m (350 ft. lbs.). Tighten pinion nut until bearing end play is taken up.
    Fig 7: Installing Pinion Nut
    G02656121Courtesy of DAIMLERCHRYSLER CORP.
  14. Slowly tighten the nut in 6.8 N-m (5 ft. lbs.) increments until desired rotating torque is achieved. Measure the rotating torque frequently to avoid over-crushing the collapsible spacer (Fig 8 ). The pinion rotating torque should be:
    • Original Bearings: 1 to 2.5 N-m (10 to 20 in. lbs.)
    • New Bearings: 1.7 to 2.5 N-m (15 to 22 in. lbs.)
      • Fig 8: Measuring Pinion Rotating Torque
      G02656122Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
  15. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
  16. Invert the differential case in the vise.
  17. Install new  ring gear bolts and alternately tighten to 108 N-m (80 ft. lbs.) (Fig 9 ).
    CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.
    Fig 9: Installing Ring Gear Bolts
    G02656123Courtesy of DAIMLERCHRYSLER CORP.
  18. Install differential in axle housing and verify gear mesh and contact pattern.
  19. Install differential cover and fill with gear lubricant.
  20. Install propeller shaft with reference marks aligned.
  21. Remove support and lower vehicle.
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