Rear Axle - 8 1/4: 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: REAR PINION BEARING CUP

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1 - INSTALLER

2 - HANDLE

NOTE: A pinion depth shim/oil baffle is placed between the rear pinion bearing cone and pinion gear. If ring and pinion gears are reused, the original pinion depth shim/oil baffle can be used. Refer to Adjustments (Pinion Gear Depth) to select the proper shim thickness if ring and pinion gear are replaced.

Apply Mopar Door Ease or equivalent lubricant to outside surface of pinion bearing cups.
Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (2). See Fig 1.

Fig 2: FRONT BEARING CUP
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1 - INSTALLER

2 - HANDLE

Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171 (2). See Fig 2.

Fig 3: PINION SEAL INSTALLER

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1 - HANDLE

2 - DIFFERENTIAL HOUSING

3 - INSTALLER

Install pinion front bearing and oil slinger, if equipped.

Apply a light coating of gear lubricant on the lip of pinion seal and install seal with Installer C-4076-B (3) and Handle C-4735 (1). See Fig 3.

Fig 4: REAR PINION BEARING

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1 - PRESS

2 - INSTALLATION

3 - PINION GEAR

4 - REAR PINION BEARING

Place pinion depth shim on the pinion.

Install rear bearing (4) on pinion gear (3) and slinger if equipped, with Installer 6448 (2) and a press (1). See Fig 4.

Fig 5: COLLAPSIBLE PRELOAD SPACER

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1 - COLLAPSIBLE SPACER

2 - SHOULDER

3 - PINION

4 - PINION DEPTH SHIM

5 - REAR BEARING

Install a new collapsible spacer (1) on pinion shaft (3) and install pinion in housing. See Fig 5.

Fig 6: Holder 6719

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1 - DIFFERENTIAL HOUSING

2 - HOLDER

3 - TORQUE WRENCH

Install companion flange with Installer C-3718 and Holder 6719A.
Install flange washer and a new nut on the pinion. The convex side of the washer must face outward.
Holding flange with Holder 6719A (2) and tighten nut with torque wrench (3) to 285 N.m (210 ft. lbs.). See Fig 6.
CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to heed caution may result in damage.
Hold yoke with Holder 6719A and slowly tighten the nut in 6.8 N.m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure rotating torque frequently to avoid over crushing the spacer.

Fig 7: PINION ROTATION TORQUE
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1 - COMPANION FLANGE

2 - INCH POUND TORQUE WRENCH

Check pinion (1) rotating torque with an inch pound torque wrench (2). See Fig 7. The pinion gear rotating torque should be:

Original Bearings: 1 to 2 N.m (10 to 20 in. lbs.).
New Bearings: 1 to 5 N.m (10 to 30 in. lbs.).

Fig 8: RING GEAR

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1 - TORQUE WRENCH

2 - BOLTS

3 - RING GEAR

4 - DIFFERENTIAL CASE

Install ring gear (3) on differential case (4) and start two ring gear bolts (2). See Fig 8.
Invert differential case in the vise.
Install new ring gear bolts and alternately tighten to 102 N.m (75 ft. lbs.).
CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will result in damage.
Install differential in axle housing and verify gear mesh refer to Adjustments (Gear Contact Pattern).