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Pinion Gear/Ring Gear: 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: Install Rear Pinion Bearing Cup
GC0028633Courtesy of DAIMLERCHRYSLER CORP.
NOTE: Ring and pinion gears are a matched set. Do not 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.
  1. Apply Mopar Door Ease or stick lubricant to outside surface of pinion bearing cups.
  2. Install rear pinion bearing cup with Installer C-4308 (1) and Handle C-4171 (20).
    Fig 2: Install Front Pinion Bearing Cup
    GC0028634Courtesy of DAIMLERCHRYSLER CORP.
  3. Install front pinion bearing cup with Installer D-130 (1) and Handle C-4171 (2).
    Fig 3: Pinion Seal Installer
    GC0028607Courtesy of DAIMLERCHRYSLER CORP.
  4. Install front pinion bearing.
  5. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972A (1) and Handle C-4171 (2).
    Fig 4: Install Depth Shim on Pinion Gear
    GC0028639Courtesy of DAIMLERCHRYSLER CORP.
  6. Install proper thickness depth shim (1) on pinion gear (2).
    Fig 5: Install Rear Bearing on Pinion Gear
    GC0028635Courtesy of DAIMLERCHRYSLER CORP.
  7. Install rear bearing (4) and slinger if equipped, on pinion gear (3) with Installer 6448A (2) and a press (1).
    Fig 6: Install Collapsible Spacer on Pinion Gear
    GC0028638Courtesy of DAIMLERCHRYSLER CORP.
  8. Install new  collapsible spacer (1) on pinion gear and install pinion in housing.
  9. Tap pinion flange onto the pinion.
  10. Install flange washer and a new nut on pinion and tighten pinion nut until there is zero end play.
  11. With a torque wrench and Flange Wrench C-3281 tighten the pinion nut to 285 N.m (210 ft. lbs.).
    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. Failure to follow these instructions will result in damage.
    Fig 7: Torque To Rotate
    GC0028606Courtesy of DAIMLERCHRYSLER CORP.
  12. Slowly tighten the nut in 6.8 N.m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure rotating torque frequently with an inch pound torque wrench (2) to avoid over crushing the collapsible spacer.
  13. 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.).
    Fig 8: Install Ring Gear Bolts
    GC0028637Courtesy of DAIMLERCHRYSLER CORP.
  14. Position exciter ring on differential case. With a brass drift slowly and evenly tap the exciter ring into position.
  15. Position ring gear on the differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
  16. Invert the differential case in the vise.
  17. Install new  ring gear bolts (2) and alternately tighten to 102 N.m (75 ft. lbs.).
    CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions may result in fractured bolts causing extensive damage.
  18. Install differential in housing and verify gear mesh, backlash and contact pattern.
  19. Install differential cover.
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