Front Axle - 186FIA: Gear-Pinion/Ring: Installation

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: FRONT PINION BEARING CUP

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1 - INSTALLER

2 - HANDLE

Install front pinion bearing, and oil slinger if equipped.
Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer 8681.
NOTE: Pinion depth shims are placed between the rear pinion bearing and the pinion gear 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.
Apply Mopar Door Ease or equivalent lubricant to outside surface of pinion bearing cups.
Install rear bearing cup with Installer C-4308 and Handle C-4171.

Install front bearing cup with Installer D-146 (1) and Handle C-4171 (1). See Fig 1.

Fig 2: REAR PINION BEARING

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1 - INSTALLER

2 - OIL SLINGER

3 - PINION GEAR

4 - REAR PINION BEARING

5 - PRESS

Install rear pinion bearing (4) and oil slinger/depth shim (2) onto the pinion shaft (3) with Installer 6448 (1) and a press (1). See Fig 2.

Fig 3: COLLAPSIBLE PRELOAD SPACER

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1 - COLLAPSIBLE SPACER

2 - SHOULDER

3 - PINION GEAR

4 - OIL SLINGER

5 - REAR BEARING

Install a new collapsible spacer (1) on pinion shaft (3) and install the pinion into the housing. See Fig 3.
Install pinion companion flange, with Installer W-162-D, Cup 8109 and Spanner Wrench 6958.

Fig 4: PINION FLANGE NUT
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1 - SPANNER WRENCH

2 - PINION COMPANION FLANGE
Install pinion a new nut onto the pinion gear and tighten the nut to 216 N.m (160 ft. lbs.). Do not over-tighten.
CAUTION: Never loosen pinion gear nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.
Use Spanner Wrench 6958 (1), a length of 1 in. pipe and a torque wrench set at 678 N.m (500 ft. lbs.) and crush collapsible spacer until bearing end play is taken up. See Fig 4.

Fig 5: PINION ROTATING TORQUE
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1 - PINION COMPANION FLANGE

2 - TORQUE WRENCH
Slowly tighten the nut in 6.8 N.m (5 ft. lb.) increments until the required rotating torque is achieved. Measure rotating torque frequently to avoid over crushing the collapsible spacer.

Rotate the pinion a minimum of ten times. Verify pinion (1) rotates smoothly and check rotating torque with an inch pound torque wrench (2). Pinion gear rotating torque is: See Fig 5.

Original Bearings: 1 to 2.25 N.m (10 to 20 in. lbs.).
New Bearings: 1.69 to 2.82 N.m (15 to 25 in. lbs.).

Fig 6: RING GEAR BOLTS

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1 - TORQUE WRENCH

2 - RING GEAR BOLTS

3 - RING GEAR

4 - DIFFERENTIAL CASE

Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
Invert differential case (4) in the vise. Install new ring gear (3) bolts (2) and alternately tighten to 108 N.m (80 ft. lbs.). See Fig 6.
CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.
Install differential in housing and verify differential bearing preload, gear mesh and contact pattern.