Gear, Ring And Pinion: Installation: Installation

WARNING: This page is about a different car, the 2016 Jeep Wrangler and 2015 Jeep Wrangler. 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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Install oil baffle in rear bearing cup bore then install rear bearing cup with Installer (special tool #C-4308, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 2: Identifying Front Bearing Cup Installer
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Install front bearing cup with Installer (special tool #D-146, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 3: Identifying Front Pinion Bearing
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Install front pinion bearing (1) into the housing.

Fig 4: Identifying Oil Slinger
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Install front pinion bearing oil slinger (1) into the housing.

Fig 5: Seal Installer
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Apply a light coating of gear lubricant on pinion seal lip and install seal with Installer (special tool #8681, Installer, Seal) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).

Fig 6: Identifying Pinion Depth Shim And Pinion Shaft
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Install pinion depth shim (1) on pinion shaft (2).

Fig 7: Installing Rear Bearing On Pinion
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Install rear pinion bearing (4) on pinion gear (3) with Installer (special tool #C-4040, Installer, Bearing) (2) and a press (1).

Fig 8: Identifying Collapsible Spacer And Pinion Shaft
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Install NEW collapsible spacer (1) on pinion shaft (2) and install pinion into the housing.

Fig 9: Identifying Companion Flange And Installer
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Install pinion flange (1) with Installer (special tool #8112, Screw) (2) and Cup (special tool #8109, Cup).

Fig 10: Flange Holder
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Install NEW pinion nut.
With Flange Wrench (special tool #C-3281, Holder, Flange) (2) and torque wrench tighten pinion nut to 217 N.m (160 ft. lbs.).

Fig 11: Checking Torque To Rotate Pinion
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Using Flange Wrench (special tool #C-3281, Holder, Flange) and torque wrench set at 542 N.m (400 ft. lbs.). Slowly tighten the nut in 6.8 N.m (5 ft. lb.) increments until the pinion torque to rotate is achieved. Measure pinion (1) torque to rotate with an inch pound torque wrench (2) frequently to avoid over crushing the collapsible spacer.
Pinion Torque To Rotate (PTTR) is:
- Original Bearings: 1.13 - 2.26 N.m (10 - 20 in. lbs.).
- New Bearings: 1.7 - 3.4 N.m (15 - 30 in. lbs.).
CAUTION:
If more than 542 N.m (400 ft. lbs.) torque is required to crush the collapsible spacer, the spacer is defective and must be replaced. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions may result in damage.

Fig 12: Identifying Ring Gear & Bolts
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Install ring gear with NEW ring gear bolts (1) and alternately tighten to the proper Torque Specifications. Refer to SPECIFICATIONS .
CAUTION:
Never reuse ring gear bolts. Failure to follow these instructions may result in damage.
Install differential case in to axle housing. Refer to CASE ASSEMBLY, DIFFERENTIAL, INSTALLATION .

Fig 13: Checking Torque To Rotate Pinion
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Measure differential Total Torque To Rotate (TTTR) with an inch pound torque wrench (2) before installing the axle shafts. This will verify differential bearing preload.
Total Torque To Rotate is: Pinion Torque To Rotate (PTTR) plus 0.79 - 1.24 N.m (7 - 11 in lbs.).

NOTE:

If TTTR is too high, decrease shim thickness equally from both sides of the differential and check TTTR again. If TTTR is too low, increase shim thickness equally to both sides of the differential and check TTTR again.