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 matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjustments for Pinion Gear Depth Setting.

Apply Mopar Door Ease or equivalent stick lubricant to outside surface of pinion bearing cups.
Install rear pinion bearing cup (Fig 1 ) with Installer C-4308 and Driver Handle C-4171 and verify cup is seated.

Fig 1: Installing Rear Pinion Bearing Cup
Courtesy of DAIMLERCHRYSLER CORP.
Install front pinion bearing cup (Fig 2 ) with Installer D-130 and Handle C-4171 and verify cup is seated.

Fig 2: Installing Front Pinion Bearing Cup
Courtesy of DAIMLERCHRYSLER CORP.
Lubricate and install front pinion bearing and oil slinger if equipped.
Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-B and Handle C-4735-1 (Fig 3 ).

Fig 3: Installing Pinion Seal
Courtesy of DAIMLERCHRYSLER CORP.
Install pinion depth shim (Fig 4 ) on the pinion shaft.

Fig 4: Installing Pinion Depth Shim
Courtesy of DAIMLERCHRYSLER CORP.
Install rear pinion bearing and slinger if equipped, on the pinion (Fig 5 ) with Installer 6448 and a press.

Fig 5: Installing Rear Pinion Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install a new collapsible spacer on the pinion gear shaft (Fig 6 ).

Fig 6: Installing Collapsible Spacer
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Lubricate rear pinion bearing and install pinion into the housing.
Install companion flange with Installer C-3718 and Holder 6719
Install bolts into two of the threaded holes in the companion flange 180° apart.
Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play.
With a torque wrench tighten the pinion nut to 285 N.m (210 ft. lbs.) (Fig 7 ).
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.

Fig 7: Tightening Pinion Nut
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Slowly tighten the nut in 6.8 N.m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig 8 ).

Fig 8: Measuring Pinion Rotation Torque
Courtesy of DAIMLERCHRYSLER CORP.
Check pinion rotating torque with an inch pound torque wrench (Fig 8 ). The pinion rotating torque should be:
- Original Bearings: 1 to 3 N.m (10 to 20 in. lbs.).
- New Bearings: 2 to 5 N.m (15 to 35 in. lbs.).
Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position.
Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
Invert the differential case in the vise.
Install new ring gear bolts and alternately tighten to 102 N.m (75 ft. lbs.) (Fig 9 )
CAUTION: Never reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage.

Fig 9: Installing Ring Gear Bolts
Courtesy of DAIMLERCHRYSLER CORP.
Install differential in housing and verify gear mesh, backlash and contact pattern.
Install differential cover and fill with gear lubricant.
Install propeller shaft with reference marks aligned.
Remove support and lower vehicle.