Front Axle - 186FBI

PINION GEAR/RING GEAR

REMOVAL

NOTE: The ring gear and pinion are serviced as a matched set. Never replace one gear without replacing the other matching gear.

1. Raise and support vehicle
2. Mark pinion companion flange and propeller shaft for installation alignment.
3. Remove propeller shaft from pinion companion flange and tie propeller shaft to underbody.
4. Remove differential from axle housing.





5. Place differential case in a vise with soft metal jaw (Fig. 51).
6. Remove bolts holding ring gear to differential case.

NOTE: On Veri-Lok differential the side bearing and oil feed plenum must be removed before removing the ring gear bolts.





7. Driver ring gear off the differential case with a rawhide hammer (Fig. 51).





8. With Spanner Wrench 6958 and a short length of 1 inch pipe, hold pinion companion flange and remove pinion nut and washer (Fig. 52).
9. Remove pinion companion flange from pinion shaft with Remover C-452 and Flange Wrench C-3281.





10. Remove pinion gear and collapsible spacer from housing (Fig. 53).





11. Remove front pinion bearing cup, bearing, oil slinger and pinion seal with Remover C-4345 and Handle C-4171 (Fig. 54).





12. Remove rear pinion bearing cup (Fig. 55) with Remover D-149 and Handle C-4171.





13. Remove collapsible preload spacer from pinion gear (Fig. 56).





14. Remove rear pinion bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-39 (Fig. 57). Remove oil slinger/pinion depth shim from the pinion shaft and record thickness.

INSTALLATION

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and the pinion head to achieve proper ring and pinion gear mesh. If ring and pinion gears are reused, the pinion oil slinger/depth shim should not require replacement. Refer to Adjustments (Pinion Gear Depth) to select the proper thickness shim before installing pinion gear.

1. Apply Mopar Door Ease or equivalent lubricant to outside surface of pinion bearing cups.





2. Install rear bearing cup with Installer D-146 and Handle C-4171 and verify cup is seated (Fig. 58).





3. Install bearing cup with Installer D-130 and Handle C-4171 (Fig. 59) and verify cup is seated.
4. Install front pinion bearing, and oil slinger if equipped.
5. Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer 8890.





6. Install rear pinion bearing and oil slinger/depth shim onto the pinion shaft with Installer W262 and a press (Fig. 60).





7. Install a new collapsible spacer on pinion shaft and install the pinion into the housing (Fig. 61).
8. Install pinion companion flange, with Installer W-162-13, Cup 8109 and Spanner Wrench 6958.
9. Install pinion washer and a new nut onto the pinion gear and tighten the nut to 298 Nm (220 ft. lbs.). Do not over-tighten.

CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed.

NOTE: New collapsible spacers require high initial torque to start the collapsing of the spacer. This may reach 678 Nm (500 ft. lbs.).





10. Use Flange Wrench 6958, a length of 1 inch pipe and a torque wrench set at 500 Nm (368 ft. lbs.) and crush collapsible spacer until bearing end play is taken up (Fig. 62).





11. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the required rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 63).
12. Rotate the pinion a minimum of ten times. Verify pinion rotates smoothly and check rotating torque with an inch pound torque wrench (Fig. 63). Pinion gear rotating torque is:
- Original Bearings: 1 - 2.25 Nm (10 - 20 in. lbs.).
- New Bearings: 1.7 - 3.4 Nm (15 - 30 in. lbs.).
13. Invert the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
14. Invert the differential case in the vise.





15. Install new ring gear bolts and alternately tighten to 108 Nm (80 ft. lbs.) (Fig. 64).

CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.

NOTE: If equipped with Veri-Lok differential install oil feed plenum and side bearing.

16. Install differential in housing and verify differential bearing preload, gear mesh and contact pattern. Refer to Adjustment for procedure.
17. Install differential cover and fill with gear lubricant.
18. Install propeller shaft with reference marks aligned.
19. Remove supports and lower vehicle.