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Front Axle - C200FE: Gear-Pinion/Ring: Installation

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Ring Gear Installer
GC0028540Courtesy of DAIMLERCHRYSLER CORP.
  1. Install left hand thread  ring gear Installer Bolts 9533 (1) through differential (2) and into ring gear (3). Tighten nuts on installer bolts evenly and draw ring gear onto differential case.
  2. Remove installer bolts and install new left hand thread  ring gear bolts and tighten to 102 N.m (75 ft. lbs.).
    Fig 2: Front Pinion Cup Installer
    GC0028533Courtesy of DAIMLERCHRYSLER CORP.
  3. Install front pinion bearing cup into housing, with Installer D-129 (1) and Handle C-4171 (2).
    Fig 3: Pinion Height Select Shim
    GC0028537Courtesy of DAIMLERCHRYSLER CORP.
  4. Install pinion depth shim (1) in rear pinion bearing cup bore (2).
    Fig 4: Rear Pinion Cup Installer
    GC0028534Courtesy of DAIMLERCHRYSLER CORP.
  5. Install rear pinion bearing cup into housing, with Installer D-111 (1) and Handle C-4171 (2).
    Fig 5: Bearing Heater
    GC0028539Courtesy of DAIMLERCHRYSLER CORP.
    WARNING: Use welding gloves when handling heated components.
    CAUTION: A bearing heater is used to assembly some components. Use only an approved heater and only heat components to 100 - 177° Celsius (212 - 350° Fahrenheit). Never leave components on heater for and extended amount of time. If component is discolored after heating, component has been overheated and must not be used. Failure to follow these instructions will result in damage.
  6. Heat rear pinion bearing (1) with bearing heater (2).
  7. Using welding gloves, install rear bearing on pinion shaft.
    Fig 6: Spacer
    GC0028535Courtesy of DAIMLERCHRYSLER CORP.
  8. Install spacer (1) from pinion shaft (2) with the beveled side facing the gear.
    Fig 7: Collapsible Spacer
    GC0028536Courtesy of DAIMLERCHRYSLER CORP.
  9. Install collapsible spacer (1) from pinion shaft (2).
    Fig 8: Front Pinion Bearing Installer
    GC0028541Courtesy of DAIMLERCHRYSLER CORP.
  10. Install pinion in housing.
  11. Install front pinion bearing into the housing (1) on the pinion shaft with Installer 9616 (2). Thread installer onto the pinion shaft then tighten installer nut.
    Fig 9: Pinion Flange Installer
    GC0028542Courtesy of DAIMLERCHRYSLER CORP.
  12. Install pinion seal with Installer 9514.
  13. Install pinion flange (1) on pinion with Installer 9616 (2). Tap flange on pinion, then thread installer center bolt on pinion shaft and draw flange onto the pinion.
    Fig 10: Flange Holder
    GC0028538Courtesy of DAIMLERCHRYSLER CORP.
  14. Hold pinion flange (1) with Flange Wrench C-3281 (2) and tighten pinion nut until torque to rotate is 1.5 to 1.9 N.m (13 to 17 in. lbs.).
    Fig 11: Collared Nut
    GC0028440Courtesy of DAIMLERCHRYSLER CORP.
  15. Cut the pinion nut collar.
  16. Bend nut collar so it touches the wall of the slot in the pinion shaft.
  17. Install differential.
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