DRIVELINE/AXLES

Rear Axle - 200MM - Chrysler 300

DESCRIPTION
DESCRIPTION

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Fig. 1: Axle Section View
Courtesy of CHRYSLER GROUP, LLC

1 - BEARING, PINION TAIL 6 - DIFFERENTIAL

2 - SHIM, PINION DEPTH 7 - RING, SNAP
3 - BEARING, PINION HEAD 8 - COVER, AXLE
4 - GEAR/SHAFT, PINION 9 - GEAR, RING
5 - BEARING, DIFFERENTIAL SIDE

The 200 MM RII (Rear-Independent-Iron) axle is an independent assembly with a cast iron housing
and differential. The 200 MM RII uses an open differential which is supported by two tapered roller
bearings located on either side of the case. Differential bearing preload and ring gear backlash are
controlled with select snap-rings located on the outside of the differential bearing cups. Pinion height
is set with a select shim located under the rear pinion bearing cup.

The 200 axle is available only in all-wheel-drive (AWD) models, and in V-6 engine-equipped rear-
wheel-drive (RWD) models, and is available in a 3.07 gear ratio.

AXLE IDENTIFICATION
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Fig. 2: Axle Identification Tag
Courtesy of CHRYSLER GROUP, LLC

The 200 MM axle utilizes a barcoded label (1) which is adhered to the top of the axle housing as
shown in illustration. The following information is found on the identification label:

Traceability Code (Plant Use)

Axle Part Number
Axle Gear Ratio

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - AXLE

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth,
tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and
squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific
type of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then
accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast
through the peak-noise range. If the noise stops or changes greatly:

Check for insufficient lubricant.

Incorrect ring gear backlash.
 Gear damage.

Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during
vehicle turns. A worn pinion shaft can also cause a snapping or a knocking noise.

BEARING NOISE

The differential and pinion bearings can produce noise when worn or damaged. Bearing noise can be
either a whining, or a growling sound.

Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion
bearing noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the
differential. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing
noise is heard during a coast, the front pinion bearing is the source.

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Worn or damaged differential bearings usually produce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differential bearing noise is also constant and varies only
with vehicle speed.

Wheel hub bearings produce noise and vibration when worn or damaged. The noise generally
changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and
to the right. This will load the bearings and change the noise level. Where axle bearing damage is
slight, the noise is usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCK

Low speed knock is generally caused by a worn U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.

VIBRATION

Vibration at the rear of the vehicle is usually caused by a:

Damaged propeller shaft.

Missing propeller shaft balance weight(s).
Worn or out-of-balance wheels.
Loose wheel lug nuts.
Worn U-joints or CV joints.
Loose/broken springs.
Damaged axle shaft bearing(s).
Loose pinion gear nut.
Excessive pinion yoke run out.
Bent halfshaft(s).
Check for loose or damaged front-end components or engine/transmission mounts. These
components can contribute to what appears to be a rear end vibration. Do not overlook engine
accessories, brackets and drive belts.

All driveline components should be examined before starting any repair.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear, can be caused by:

High engine idle speed.

Transmission shift operation.
Loose engine/transmission/transfer case mounts.
Worn U-joints or CV joints.
Worn or broken axle mount isolators.

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Loose pinion gear nut and yoke.
Excessive ring gear backlash.
Excessive side gear to case clearance.

The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the
vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear.
Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.

DIAGNOSTIC CHART
CONDITION POSSIBLE CAUSE CORRECTION
WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel 2. Replace bearing.
bearing.
DIFFERENTIAL CRACKED 1. Improper differential side 1. Replace case and inspect
bearing preload. gears and bearings for further
damage. Set differential
bearing preload properly.
2. Excessive ring gear 2. Replace case and inspect
backlash. gears and bearings for further
damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect
gears and bearings for further
damage. Avoid excessive
vehicle weight.
DIFFERENTIAL GEARS 1. Insufficient lubrication. 1. Replace scored gears. Fill
SCORED differential with the correct fluid
type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
 differential with the proper fluid
type and quantity.
3. Excessive spinning of one 3. Replace scored gears.
wheel/tire. Inspect all gears, pinion bores,
and shaft for damage. Service
as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked axle housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored pinion flange 5. Replace pinion flange and
journal. seal.
6. Axle cover not properly 6. Remove, clean, and re-seal
sealed. cover.

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AXLE OVERHEATING 1. Lubricant level low. 1. Fill differential to correct
level.
2. Improper grade of lubricant. 2. Fill differential with the
correct fluid type and quantity.
3. Bearing preload too high. 3. Readjust bearing pre-load.
4. Insufficient ring gear 4. Re-adjust ring gear
backlash. backlash.
GEAR TEETH BROKEN 1. Overloading. 1. Replace gears. Examine
other gears and bearings for
possible damage.
2. Ice-spotted pavement. 2. Replace gears and examine
remaining parts for damage.
3. Improper adjustments. 3. Replace gears and examine
remaining parts for damage.
Ensure ring gear backlash is
correct.
AXLE NOISE 1. Insufficient lubricant. 1. Fill axle with the correct fluid
type and quantity.
2. Improper ring gear and 2. Check ring gear and pinion
pinion adjustment. contact pattern. Adjust
backlash or pinion depth.
3. Unmatched ring gear and 3. Replace gears with a
pinion. matched ring gear and pinion.
4. Worn teeth on ring gear 4. Replace ring gear and
and/or pinion. pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-
load.
6. Loose differential bearings. 6. Adjust differential bearing
preload.
 7. Misaligned or sprung ring 7. Measure ring gear run-out.
gear. Replace components as
necessary.
8. Housing not machined 8. Replace housing.
properly.

STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID DRAIN AND FILL

NOTE: Note: The fluid required for use in this axle is Mopar® Synthetic Gear and Axle
Lubricant 75W-140.

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Fig. 3: Rear Axle Drain Plug
Courtesy of CHRYSLER GROUP, LLC

1. Drive the vehicle until the differential lubricant is at the normal operating temperature.
2. With vehicle in neutral, position and raise vehicle on hoist.
3. Remove rear axle drain plug and drain lubricant completely from the axle.
4. Install drain plug and tighten to 60 N.m (44 ft lbs).
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Fig. 4: Rear Axle Fill Plug
Courtesy of CHRYSLER GROUP, LLC

5. Remove fill plug (1) and fill rear axle with 1.4 L (1.5 qts.) Mopar® Synthetic Gear AND Axle
Lubricant 75W-140 and insure axle is filled to the bottom of the fill hole.
6. Install fill plug and tighten to 60 N.m (44 ft lbs).

ADJUSTMENTS
PINION DEPTH

PINION DEPTH VARIANCE

Ring gear and pinion are supplied as matched sets.

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Fig. 5: Pinion Depth Variance
Courtesy of CHRYSLER GROUP, LLC

Compensation for pinion depth variance is achieved with select shims (3). The shims are sandwiched
between the pinion head bearing cup (4) and axle housing.

If installing a new gear, note the depth variance number of the original and replacement pinion. Add
or subtract this number from the original depth shim to compensate for the difference in the depth
variances. The numbers represent deviation from the standard in thousandths of an inch. If the
number is negative, add that value to the required thickness of the depth shims. If the number is
positive, subtract that value from the thickness of the depth shim.

PINION DEPTH MEASUREMENT

Pinion depth measurement is taken with the pinion head and tail bearing cups pressed into the axle
housing without the shim.
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Fig. 6: Pinion Head Bearing Cup Installation
Courtesy of CHRYSLER GROUP, LLC

1. Press pinion head bearing cup into housing using Handle (special tool #C-4171, Driver Handle,
Universal) (1) and Installer (special tool #C-4310, Installer, Bearing) (2).

Fig. 7: Installing Pinion Tail Bearing Cup

Courtesy of CHRYSLER GROUP, LLC

2. Press pinion tail bearing cup into housing using Handle (special tool #C-4171, Driver Handle,
Universal) (1) and Installer (special tool #D-146, Installer, Bearing Cup) (2).
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Fig. 8: L-Block, Gage Block & Bearing
Courtesy of CHRYSLER GROUP, LLC

3. Assemble Pinion Height Block (special tool #6739, Block, Height) (3), Pinion Head Bearing
Cone (1), Screw (special tool #6741, Screw) (all these can be found in a Pinion Gauge Set such
as (special tool #6774, Kit, Jeep Pinion Depth)), and Pinion Height Gage Block (special tool
#9227, Gauge, Pinion Height) (2). Install assembly into axle housing and through bearing cups.

Fig. 9: Pinion Depth Gauge Tools - Typical

Courtesy of CHRYSLER GROUP, LLC
4. Install pinion tail bearing and Cone (special tool #6740, Cone) (4). Tighten Cone (special tool
#6740, Cone) by hand until 3.4 N.m (30 in. lbs.) of rotating torque is measured at Screw (special
tool #6741, Screw) (5).

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Fig. 10: Removing/Installing Arbor Discs
Courtesy of CHRYSLER GROUP, LLC

5. Install Arbor Discs (special tool #9228, Set, Arbor Disc) (1).

Fig. 11: Remove/Install Arbor Bar

Courtesy of CHRYSLER GROUP, LLC

6. Install Arbor Bar (special tool #D-115-3, Arbor) (1) from a Pinion Gauge Set such as (special
 tool #6774, Kit, Jeep Pinion Depth).

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Fig. 12: Pinion Gage Setup
Courtesy of CHRYSLER GROUP, LLC

7. Verify pinion depth setup is as shown in illustration.

Fig. 13: Indicator/Scooter Block Setup

Courtesy of CHRYSLER GROUP, LLC

8. Install Dial Indicator (special tool #9524, Indicator, Dial) (1) to Scooter Block (special tool #D-
115-2A, Block, Scooter) (2) (from a Pinion Gauge Set such as (special tool #6774, Kit, Jeep
Pinion Depth)). Secure with set-screw (3).
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Fig. 14: Zero Dial Indicator On L-Block
Courtesy of CHRYSLER GROUP, LLC

9. Install Indicator/Block assembly to top of Pinion Height Block (special tool #6739, Block, Height)
(1). Zero indicator on top surface.

Fig. 15: Measure And Record Required Shim

Courtesy of CHRYSLER GROUP, LLC

10. Slide indicator probe off of height block and onto Arbor Bar (special tool #D-115-3, Arbor) (2).
As indicator contacts Arbor Bar (2), indicator needle will rotate clockwise. Continue moving
indicator probe to the crest of the arbor bar and record the highest reading.
11. Select a shim equal to the dial indicator reading minus 2.5 mm (0.09 in.). After shim installation,
check the amount of pinion bearing preload, and adjust as required to achieve the correct
 turning torque.

ADJUSTMENT - SIDE BEARING PRELOAD AND RING GEAR BACKLASH

DIFFERENTIAL SIDE BEARING PRELOAD MEASUREMENT/CORRECTION

Differential side bearing preload should be measured and adjusted after the following scenarios:

Differential case replacement

Differential side bearing replacement
Axle housing replacement
Loss or replacement of side bearing snap rings

If none of these situations apply, refer to RING GEAR BACKLASH

MEASUREMENT/CORRECTION .

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Fig. 16: Universal Spreader Adapter Plates & Spreader
Courtesy of CHRYSLER GROUP, LLC

1. Install Universal Spreader Adapter Plates (special tool #10113, Adapters, Spreader) (1), and
Spreader (special tool #W-129-B, Spreader, Differential) (2). Install a stud into the case in the
location shown in illustration. Mount Clamp (special tool #SP-5426, Clamp (Less Post)) to the
stud, and install Post (special tool #SP-5425-B, Special Post) from Dial Indicator Set (special
tool #C-3339A, Set, Dial Indicator) into the Clamp (special tool #SP-5426, Clamp (Less Post)).
Zero Metric Dial Indicator (special tool #9524, Indicator, Dial) (3) in the location shown in
illustration to measure axle housing spread.
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Fig. 17: Expanding/Contracting Spreader
Courtesy of CHRYSLER GROUP, LLC

2. If differential side bearing cups and snap rings are removed at this point, skip to Step 6.
Otherwise, expand spreader to spread axle housing no more than 0.30 mm (0.012 in.).

Fig. 18: Snap Ring Removal/Installation

Courtesy of CHRYSLER GROUP, LLC

3. Remove both differential side bearing snap rings (1). Tag snap ring to ensure installation in
original position.
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Fig. 19: Measuring Side Bearing Snap Ring
Courtesy of CHRYSLER GROUP, LLC

4. Measure and record snap ring (2) thickness for later use.

Fig. 20: Expanding/Contracting Spreader

Courtesy of CHRYSLER GROUP, LLC

5. Relax spreader (1) to relieve tension on axle housing.

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Fig. 21: Snap Ring Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

6. Install right (pinion) side bearing cup and snap ring (1).

Fig. 22: Expanding/Contracting Spreader

Courtesy of CHRYSLER GROUP, LLC

7. Zero dial indicator.

8. Expand spreader (1) to spread axle housing no more than 0.30 mm (0.012 in.).
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Fig. 23: Snap Ring Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

9. Install left (ring gear) side bearing cup and snap ring (1).

Fig. 24: Expanding/Contracting Spreader

Courtesy of CHRYSLER GROUP, LLC

10. Relax spreader (1) to relieve tension on axle housing.

11. Measurement showing on indicator is the axle housing retained spread. Proper differential side
bearing preload is achieved with an axle housing retained spread of 0.18-0.23 mm (0.007-0.009
in.).
12. If retained spread is less than 0.18 mm (0.007 in.), increase snap ring thickness at each side in
 equal increments.
13. If retained spread is greater than 0.23 mm (0.009 in.), decrease snap ring thickness at each
side in equal increments.

RING GEAR BACKLASH MEASUREMENT/CORRECTION

Differential Ring Gear Backlash should be measured and adjusted after the following scenarios:

1. Ring and pinion gear replacement

2. Pinion head bearing replacement
3. Pinion depth (shim) adjustment
4. Differential case replacement
5. Differential side bearing replacement
6. Axle housing replacement

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NOTE: If Spreader (special tool #W-129-B, Spreader, Differential) is installed,
make sure tension on axle housing is relieved.

Fig. 25: Universal Spreader Adapter Plates & Spreader

Courtesy of CHRYSLER GROUP, LLC

7. Install Universal Spreader Adapter Plates (special tool #10113, Adapters, Spreader) (1), and
Spreader (special tool #W-129-B, Spreader, Differential) (2). Install a stud into the case in the
location shown in illustration. Mount Clamp (special tool #SP-5426, Clamp (Less Post)) to the
stud, and install Post (special tool #SP-5425-B, Special Post) from Dial Indicator Set (special
tool #C-3339A, Set, Dial Indicator) into the Clamp (special tool #SP-5426, Clamp (Less Post)).
Zero Metric Dial Indicator (special tool #9524, Indicator, Dial) (3) in the location shown in
illustration to measure axle housing spread.
8. Rotate ring gear one direction to take up clearance to pinion. Verify indicator tip is in contact
with ring gear and zero indicator. Rotate ring gear back and forth and record measurement.
 Ring gear backlash should be 0.13-0.18 mm (0.005-0.007 in.). Verify back lash measurement in
four positions.

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Fig. 26: Backlash Shim Correction
Courtesy of CHRYSLER GROUP, LLC

9. If backlash measurement is less than 0.13 mm (0.005 in.), it is necessary to decrease the snap
ring thickness on the ring gear (left) side, and increase the thickness on the pinion (right) side.
10. If backlash measurement is greater than 0.18 mm (0.007 in.), it is necessary to increase the
snap ring thickness on the ring gear (right) side, and decrease the thickness on the pinion (left)
side.

GEAR CONTACT PATTERN

The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing.
It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact patterns.

1. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring
gear teeth.
2. Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of
the pinion. This will provide a more distinct contact pattern.
3. With a boxed end wrench on a ring gear bolt, rotate the differential case one complete
revolution in both directions while a load is being applied from shop towel.

The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will
squeegee the compound to the areas with the least amount of contact. Note and compare patterns on
the ring gear teeth to Gear Tooth Contact Patterns chart and adjust pinion depth and gear backlash
as necessary. Refer to Fig. 27.

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Fig. 27: Gear Tooth Contact Patterns

Courtesy of CHRYSLER GROUP, LLC

SPECIFICATIONS
SPECIFICATIONS

DESCRIPTION SPECIFICATION
Ring Gear Diameter 200 mm (7.87 in.)
Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.)
Axle Housing Retained Spread 0.18 mm to 0.23 mm (0.007 in. to 0.009 in.)
Select Snap Ring Size 3.60-4.68 mm (0.14-0.18 in.) In 0.02mm
(0.0007 in.) increments
Select Pinion Shim Size 1.40-2.50mm (0.05-0.10 in.) In 0.01mm (0.0004
in.) increments
Pinion Torque To Rotate 2.25N.m (20 in. lbs.)
Total Torque To Rotate (Approx.) 3.38N.m (30 in. lbs.)

TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.

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Plug, Rear Axle 60 44 -
Drain/Fill
Bolt, Differential Cover 30 +45° 22 + 45° -
Bolt, Ring Gear-to- 85 64 -
Differential Case
Bolt, Axle Housing-to-
220 162 -
Crossmember
Bolt/Nut, Axle Front
65 48 -
Mount Isolator
Bolt/Nut, Propeller
Shaft Coupler-to-Axle 58 43 -
Flange

REMOVAL
REMOVAL

NOTE: This procedure requires the compression of the rear suspension to ride height.
A drive-on hoist should be used. If a drive-on hoist is not used, screw-style
under-hoist jack stands are required to compress the rear suspension,
facilitating rear halfshaft removal.

CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may
cause the boot to pucker or crease, reducing the service life of the boot
and joint. Avoid over angulating or stroking the C/V joints when handling
the halfshaft.
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Fig. 28: Rear Axle Drain Plug
Courtesy of CHRYSLER GROUP, LLC

1. With vehicle in neutral, position and raise vehicle on hoist.

2. Using 14mm hex, remove axle drain plug (1) and drain rear axle fluid into container suitable for
fluid reuse.
3. Install drain plug (1) and torque to 60 N.m (44 ft. lbs.) torque.

Fig. 29: Identifying Clamps & Rear Exhaust System

Courtesy of CHRYSLER GROUP, LLC

4. Remove rear exhaust system (2) on dual-outlet exhaust models, otherwise, lower exhaust
system at rear hanger(s) to provide adequate clearance.
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Fig. 30: Alignment Marks AT Shaft And Flange
Courtesy of CHRYSLER GROUP, LLC

5. Apply alignment index marks (3) to the propeller shaft rubber coupler (1) and axle flange (2).

Fig. 31: Propeller Shaft AT Rear Axle Flange

Courtesy of CHRYSLER GROUP, LLC

6. Remove three propeller shaft coupler-to-axle flange bolt/nuts.

 Fig. 32: Halfshaft Removal (V6 Models)

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Courtesy of CHRYSLER GROUP, LLC

7. Using suitable screwdriver (1), partially disengage halfshaft(s) (2) from axle assembly.

Fig. 33: Supporting Rear Axle With Jack Stands Transmission Jack
Courtesy of CHRYSLER GROUP, LLC

8. If a drive-on hoist is used, position transmission jack (1) to rear axle assembly. If a drive-on
hoist is not used, compress rear suspension using screw-style under-hoist jack stands (2), then
position transmission jack to rear axle assembly.
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Fig. 34: Rear Axle Forward Mount Isolator & Bolt/Nut
Courtesy of CHRYSLER GROUP, LLC

9. Remove rear axle forward mount isolator (1) bolt/nut (2).

10. Remove two rear axle-to-crossmember bolts (1).

Fig. 35: Propeller Shaft Supported

Courtesy of CHRYSLER GROUP, LLC

11. Carefully lower rear axle. While lowering axle, separate propeller shaft from axle and support
with suitable rope or wire (1).
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Fig. 36: Halfshaft Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

12. Lower axle just enough to remove both halfshafts one at a time. Shift axle assembly in one
direction, compressing one halfshaft while removing the other (1). Use caution to protect axle
seal and journal.
13. Remove axle assembly from vehicle and transfer to bench.

INSTALLATION
INSTALLATION

Fig. 37: Axle Seal Installation

Courtesy of CHRYSLER GROUP, LLC

1. Install new axle seal(s) (1) using (special tool #9223A, Drift) (2) if a new seal is required.

NOTE: Always use (special tool #9099, Seal Protector, Differential Output) when
installing half shaft into the transaxle. If the Seal Protector is new please
split at seam before using.

NOTE: Use care when installing halfshaft to axle assembly. The halfshaft
installation angle should be minimized to avoid damage to seal upon
installation.

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Fig. 38: Identifying Rear Axle, Rear Driveshaft, Rear Axle Flange, and Halfshafts
Courtesy of CHRYSLER GROUP, LLC

NOTE: While raising rear axle reposition rear drive shaft to rear axle flange.

2. Install new circlip(s), on halfshafts (3).

3. Raise axle just enough to install both halfshafts one at a time. Be careful not to damage axle
seals using (special tool #9099, Seal Protector, Differential Output) (1). Shift axle assembly in
one direction, compressing one halfshaft while installing the other.
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Fig. 39: Halfshaft Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

4. Verify proper installation by pulling outward on joint by hand.

Fig. 40: Alignment Marks AT Shaft And Flange

Courtesy of CHRYSLER GROUP, LLC

5. Raise rear axle assembly into position. Align propeller shaft index marks (3) and start propeller
shaft coupler-to-axle bolt/nuts by hand.
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Fig. 41: Rear Axle Forward Mount Isolator & Bolt/Nut
Courtesy of CHRYSLER GROUP, LLC

6. Install two rear axle-to-crossmember bolts (1) and torque to 220 N.m (162 ft. lbs.).
7. Install rear axle front mount isolator (1) as shown in illustration and torque bolt/nut to 65 N.m (48
ft. lbs.).

Fig. 42: Supporting Rear Axle With Jack Stands Transmission Jack
Courtesy of CHRYSLER GROUP, LLC

8. Again verify halfshaft inner joints are fully engaged to axle assembly.
9. Remove transmission jack (1).
10. If used, remove screw-type under-hoist jack stands (2).
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Fig. 43: Propeller Shaft AT Rear Axle Flange
Courtesy of CHRYSLER GROUP, LLC

11. Tighten the propeller shaft coupler-to-axle flange bolt/nuts. Refer to SPECIFICATIONS .

SPECIAL TOOLS
SPECIAL TOOLS

10113 - Adapters, Spreader

(Originally Shipped In Kit Number(s) 9566-SUP2.)
1026 - Puller
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC.)
6448A - Installer, Bearing/Gear
(Originally Shipped In Kit Number(s) 6947, 8667, 8837, 8867.)
6739 - Block, Height
(Originally Shipped In Kit Number(s) 6730, 9516A-CAN, 9540, 9541.)
6740 - Cone
(Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.)
6741 - Screw
(Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.)
6774 - Kit, Jeep Pinion Depth
(Originally Shipped In Kit Number(s) 6774.)
8255 - Installer
(Originally Shipped In Kit Number(s) 8283, 8283CC, 8527, 8527CC, 8575, 8575CC, 9975.)
9084 - Remover, Pinion Bearing Cup
(Originally Shipped In Kit Number(s) 9329, 9515, 9516, 9516-CAN, 9517, 9517-CAN, 9518,
9519, 9540, 9541, 9694.)

9099 - Seal Protector, Differential Output

(Originally Shipped In Kit Number(s) 9324, 9324CC.)
9223A - Drift
(Originally Shipped In Kit Number(s) 9202, 9202CC, 9329-SUP, 9516-SUP, 9518-SUP,
9519-SUP, 9540-SUP.)
9226 - Adapters, Spreader
(Originally Shipped In Kit Number(s) 9329, 9515, 9516, 9516-CAN, 9517, 9517-CAN, 9518,
9519, 9540, 9541.)
9227 - Gauge, Pinion Height
(Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518,
9519, 9540-SUP, 9541-SUP.)
9228 - Set, Arbor Disc
(Originally Shipped In Kit Number(s) 9329, 9515, 9516, 9516-CAN, 9517, 9517-CAN, 9518,
9519, 9540, 9541.)
9231A - Installer, Pinion Oil Seal
(Originally Shipped In Kit Number(s) 9202, 9329, 9515, 9516, 9516-CAN, 9517, 9517-CAN,
9518, 9519, 9540, 9541, 9580, 9599.)

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9522 - Remover/Installer, Bearing Cup
(Originally Shipped In Kit Number(s) 9329, 9515, 9516, 9516-CAN, 9517, 9517-CAN, 9518,
9519, 9540, 9541.)
9523A - Installer, Bearing
(Originally Shipped In Kit Number(s) 10175, 10175, 9541.)
9524 - Indicator, Dial
(Originally Shipped In Kit Number(s) 9329, 9329-SUP, 9515-SUP2, 9516, 9516-SUP, 9517-
SUP2, 9518, 9518-SUP, 9519, 9540-SUP, 9541-SUP, 9694.)
9630 - Fixture, Diff. Case Holding
(Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518,
9519, 9540-SUP, 9541-SUP.)
9631 - Fixture, Holding
(Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518,
9519, 9540-SUP, 9541-SUP.)
C-293-37 - Block Set, Puller
(Originally Shipped In Kit Number(s) 8418, 8562, C-293-M, DD-914-CLT-L.)
C-293-PA - Puller, Press
(Originally Shipped In Kit Number(s) 8418, 8837, C-293-M.)
C-3095-A - Installer, Bearing
C-3281 - Holder, Flange
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)
C-3339A - Set, Dial Indicator
(Originally Shipped In Kit Number(s) 9202.)
C-4171 - Driver Handle, Universal
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)
C-4310 - Installer, Bearing
(Originally Shipped In Kit Number(s) C-4306.)
D-115-2A - Block, Scooter
 (Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518,
9519, 9540-SUP, 9541-SUP, 9694, 9926.)
D-115-3 - Arbor
(Originally Shipped In Kit Number(s) 8667, 9516A-CAN.)
D-146 - Installer, Bearing Cup
(Originally Shipped In Kit Number(s) 8667.)
D-149 - Remover, Bearing Cup
(Originally Shipped In Kit Number(s) 8207, 8418, C-4306.)
SP-3289 - Extension, Puller
(Originally Shipped In Kit Number(s) 9599.)
SP-5425-B - Special Post
SP-5426 - Clamp (Less Post)
W-129-B - Spreader, Differential
(Originally Shipped In Kit Number(s) 9975.)

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BEARING, DIFFERENTIAL SIDE
REMOVAL

REMOVAL

Fig. 44: Removing/Installing Differential

Courtesy of CHRYSLER GROUP, LLC

1. Remove differential assembly from axle. Refer to CASE ASSEMBLY, DIFFERENTIAL,

REMOVAL.
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Fig. 45: Bearing Removal
Courtesy of CHRYSLER GROUP, LLC

2. Remove bearings (2) from the differential case (3) with Puller/Press (special tool #C-293-PA,
Puller, Press) (5), Adapters (special tool #C-293-37, Block Set, Puller) (1) and Puller Extension
(special tool #SP-3289, Extension, Puller) (4).

INSTALLATION

INSTALLATION
 cardiagn.com
Fig. 46: Installing Differential Side Bearing
Courtesy of CHRYSLER GROUP, LLC

1. Using Installer (special tool #9523A, Installer, Bearing) (2) and Handle (special tool #C-4171,
Driver Handle, Universal) (1), press differential side bearings (3) onto differential case.

Fig. 47: Removing/Installing Differential

Courtesy of CHRYSLER GROUP, LLC

2. Install differential (1) and reassemble axle assembly.

3. Install the axle assembly. Refer to INSTALLATION.

CASE ASSEMBLY, DIFFERENTIAL

REMOVAL

REMOVAL

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Fig. 48: Axle Clamped In Vise
Courtesy of CHRYSLER GROUP, LLC

1. Remove rear axle from vehicle. Refer to REMOVAL.

2. Clamp rear axle assembly into bench vise (1).

Fig. 49: Removing/Installing Drain Plug

Courtesy of CHRYSLER GROUP, LLC

3. Remove drain plug (1) and drain fluid into container suitable for reuse.
4. Install drain plug and torque to 60 N.m (44 ft. lbs.).

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Fig. 50: Measuring Turning Torque
Courtesy of CHRYSLER GROUP, LLC

5. Using suitable torque wrench (1), measure and record rear axle assembly total turning torque.

Fig. 51: Axle Seal Removal

Courtesy of CHRYSLER GROUP, LLC

6. Using suitable screwdriver (1), remove both axle seals (2).

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Fig. 52: Axle Housing Cover & Bolts
Courtesy of CHRYSLER GROUP, LLC

7. Remove twelve axle cover-to-housing bolts (1) and remove cover (2).

Fig. 53: Universal Spreader Adapter Plates & Spreader

Courtesy of CHRYSLER GROUP, LLC

8. Install Universal Spreader Adapter Plates (special tool #10113, Adapters, Spreader) (1), and
Spreader (special tool #W-129-B, Spreader, Differential) (2). Install a stud in the location shown
in illustration. Mount Clamp (special tool #SP-5426, Clamp (Less Post)) to the stud, and install
Post (special tool #SP-5425-B, Special Post) from dial indicator set (special tool #C-3339A, Set,
Dial Indicator) into Clamp (special tool #SP-5426, Clamp (Less Post)). Zero Metric Dial Indicator
(special tool #9524, Indicator, Dial) (3) in the location shown in illustration to measure axle
housing spread.
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Fig. 54: Expanding/Contracting Spreader
Courtesy of CHRYSLER GROUP, LLC

9. Spread axle housing no more than 0.30 mm (0.012 in.).

Fig. 55: Snap Ring Removal/Installation

Courtesy of CHRYSLER GROUP, LLC

NOTE: The differential side bearing snap rings are select-fit, and control ring gear
backlash and differential side bearing preload. It is important to return
original snap rings to their original position.

10. Using suitable snap ring pliers (2), compress and remove differential side bearing snap rings
 (1). Identify and tag for proper reuse.

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Fig. 56: Expanding/Contracting Spreader
Courtesy of CHRYSLER GROUP, LLC

11. Back off Spreader (special tool #W-129-B, Spreader, Differential) (1) to relax tension on
housing.

Fig. 57: Measuring Side Bearing Snap Ring

Courtesy of CHRYSLER GROUP, LLC

12. Measure snap ring thickness and record for future use.
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Fig. 58: Removing/Installing Side Bearing Cups
Courtesy of CHRYSLER GROUP, LLC

13. Install Removal/Installation Arbor (special tool #9522, Remover/Installer, Bearing Cup) (1) into
one side of housing and push inward to release differential side bearing cup (2) from opposite
side. Repeat for other bearing.

Fig. 59: Removing/Installing Differential

Courtesy of CHRYSLER GROUP, LLC

14. Remove differential assembly from axle housing.

NOTE: Note: If difficulty removing differential is encountered due to interference

 with Spreader (special tool #W-129-B, Spreader, Differential) and Spreader
Adapter Plates (special tool #9226, Adapters, Spreader), remove spreader
and adapter plates to facilitate removal.

DISASSEMBLY

DISASSEMBLY

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Fig. 60: Ring Gear Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Remove differential ring gear-to-case bolts (1).

Fig. 61: Removing Ring Gear

Courtesy of CHRYSLER GROUP, LLC
2. Using brass drift (1), remove ring gear (2).

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Fig. 62: Bearing Removal
Courtesy of CHRYSLER GROUP, LLC

3. Remove bearings (2) from the differential case (3) with Puller/Press (special tool #C-293-PA,
Puller, Press) (5), Adapters (special tool #C-293-37, Block Set, Puller) (1) and Puller Extension
(special tool #SP-3289, Extension, Puller) (4).
 cardiagn.com
Fig. 63: Differential Mounted
Courtesy of CHRYSLER GROUP, LLC

4. Install the differential to Mounting Plate (special tool #9630, Fixture, Diff. Case Holding) (2) to
the differential (1) and then install the assembly into a bench vise.

Fig. 64: Roll Pin Removal

Courtesy of CHRYSLER GROUP, LLC

5. Drive out pinion shaft-to-case roll pin using hammer and suitable punch.
 cardiagn.com
Fig. 65: Removing Pinion Shaft
Courtesy of CHRYSLER GROUP, LLC

6. Using brass drift (2), drive out pinion shaft (1).

Fig. 66: Installing Fixture

Courtesy of CHRYSLER GROUP, LLC

7. Install Fixture (special tool #9631, Fixture, Holding) (1) into differential side gear.
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Fig. 67: Rotate Differential Gears
Courtesy of CHRYSLER GROUP, LLC

8. Rotate Fixture (special tool #9631, Fixture, Holding) (1) to gain access to and remove pinion
gears and thrust washers.

Fig. 68: Side Gears & Thrust Washers

Courtesy of CHRYSLER GROUP, LLC

9. Remove differential side gears (4) and thrust washers (5).

ASSEMBLY

ASSEMBLY
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Fig. 69: Installing Side Gears
Courtesy of CHRYSLER GROUP, LLC

1. Lubricate all differential components with hypoid gear lubricant.

2. Install differential side gears (2) and thrust washers to Fixtures (special tool #9631, Fixture,
Holding) (1) as shown in illustration.

Fig. 70: Removing/Installing Pinion Gear & Washer

Courtesy of CHRYSLER GROUP, LLC

3. Install differential pinion gears (1) and thrust washers into position across from each other.
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Fig. 71: Rotate Differential Gears
Courtesy of CHRYSLER GROUP, LLC

4. Rotate pinion gears into place using Fixture (special tool #9631, Fixture, Holding) and line up
gear centers with pinion shaft bore.

Fig. 72: Roll Pin Installation

Courtesy of CHRYSLER GROUP, LLC

5. Using a brass hammer, drive pinion shaft (3) into differential case (1), making sure to line up roll
pin bores.
6. Using suitable punch (2), drive new roll pin into position.
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Fig. 73: Measure Rotating Torque
Courtesy of CHRYSLER GROUP, LLC

7. Measure differential gear rotating torque as shown in illustration. Differential gear rotating torque
should be 5-30 N.m (44-266 in. lbs.) Rotating torque is adjusted using select side gear thrust
washers. Refer to the following chart.

Available Side Gear Thrust Washer Thicknesses

1.25 mm (0.049 in.)
1.30 mm (0.051 in.)
1.35 mm (0.053 in.)
1.40 mm (0.055 in.)
1.45 mm (0.057 in.)
1.50 mm (0.059 in.)
1.55 mm (0.061 in.)
1.60 mm (0.063 in.)
1.65 mm (0.065 in.)
 cardiagn.com
Fig. 74: Differential Mounted
Courtesy of CHRYSLER GROUP, LLC

8. Remove differential case from Mounting Plate (special tool #9630, Fixture, Diff. Case Holding)
(2).

Fig. 75: Ring Gear Bolts

Courtesy of CHRYSLER GROUP, LLC

9. Install ring gear to case. Lightly tap ring gear into position to facilitate starting of bolts.
10. Install new ring gear-to-case bolts and torque to 85 N.m (63 ft. lbs.).
 cardiagn.com
Fig. 76: Installing Differential Side Bearing
Courtesy of CHRYSLER GROUP, LLC

11. Using Installer (special tool #9523A, Installer, Bearing) (2) and Handle (special tool #C-4171,
Driver Handle, Universal) (1), press new differential side bearings (3) onto differential case.

INSTALLATION

INSTALLATION

NOTE: If replacement differential side bearings or differential case are being installed,
it is necessary to measure and adjust Differential Side Bearing Preload and
Gear Backlash. to determine proper snap ring selection. Refer to
ADJUSTMENTS.
 cardiagn.com
Fig. 77: Removing/Installing Differential
Courtesy of CHRYSLER GROUP, LLC

1. Install differential assembly (1) into axle housing.

Fig. 78: Removing/Installing Side Bearing Cups

Courtesy of CHRYSLER GROUP, LLC

2. Install differential side bearing cups (2).

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Fig. 79: Arbor & Bearing Cups
Courtesy of CHRYSLER GROUP, LLC

3. Use Removal/Installation Arbor (special tool #9522, Remover/Installer, Bearing Cup) (1) to aid
in seating side bearing cups (2).

Fig. 80: Measuring Rotating Torque

Courtesy of CHRYSLER GROUP, LLC

4. Set up Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) to measure housing spread
as shown in illustration:
1. Clamp (special tool #SP-5426, Clamp (Less Post)) (1)
2. Post (special tool #SP-5425-B, Special Post) (2)
 3. Metric Dial Indicator (special tool #9524, Indicator, Dial) (3)

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Fig. 81: Expanding/Contracting Spreader
Courtesy of CHRYSLER GROUP, LLC

5. Expand Spreader (special tool #W-129-B, Spreader, Differential) (1) to spread axle housing no
more than 0.30 mm (0.012 in.).

NOTE: The differential side bearing snap rings are select-fit, and control ring gear
backlash and differential side bearing preload. It is necessary to return
snap rings to their original position. If replacement differential side
bearings or differential case are being installed. to determine proper snap
ring selection. Refer to ADJUSTMENTS.
 cardiagn.com
Fig. 82: Snap Ring Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

6. Using suitable snap ring pliers (2), install differential side bearing snap rings (1).

Fig. 83: Expanding/Contracting Spreader

Courtesy of CHRYSLER GROUP, LLC

7. Back off Spreader (special tool #W-129-B, Spreader, Differential) (1) to relax tension on
housing.
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Fig. 84: Axle Seal Installation
Courtesy of CHRYSLER GROUP, LLC

8. Install axle seals (1) using Installer (special tool #9223A, Drift) (2).

Fig. 85: Universal Spreader Adapter Plates & Spreader

Courtesy of CHRYSLER GROUP, LLC

9. Remove Dial Indicator Kit, Stud, Spreader (special tool #W-129-B, Spreader, Differential) (2)
and Universal Spreader Adapter Plates (special tool #10113, Adapters, Spreader) (1).
 cardiagn.com
Fig. 86: Sealant Application
Courtesy of CHRYSLER GROUP, LLC

10. Apply 4mm (0.157 in.) bead (2) of Mopar® Axle RTV to axle housing cover (1) as shown in
illustration.

Fig. 87: Axle Housing Cover & Bolts

Courtesy of CHRYSLER GROUP, LLC

11. Install cover to axle housing. Install and torque cover-to-housing bolts to 30 N.m (22 ft. lbs.) +
45°.
12. Install the rear axle. Refer to INSTALLATION.
COVER, DIFFERENTIAL
REMOVAL

REMOVAL

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Fig. 88: Axle Housing Cover & Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Remove axle assembly from vehicle. Refer to REMOVAL.

2. Remove axle housing cover bolts (1).
3. Using suitable screwdriver, remove axle housing cover (2).

INSTALLATION

INSTALLATION
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Fig. 89: Sealant Application
Courtesy of CHRYSLER GROUP, LLC

1. After thoroughly cleaning axle housing cover (1), apply a 4 mm (0.157 in.) bead (2) of Mopar®
Axle RTV as shown in illustration.

Fig. 90: Axle Housing Cover & Bolts

Courtesy of CHRYSLER GROUP, LLC

2. Immediately install cover (2) to axle housing. Install and torque axle housing cover bolts (1) to
30 N.m (22 ft. lbs.) + 45°.
3. Install axle assembly to vehicle. Refer to INSTALLATION.
GEAR, RING AND PINION
REMOVAL

REMOVAL

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Fig. 91: Ring Gear Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Remove differential assembly. Refer to CASE ASSEMBLY, DIFFERENTIAL, REMOVAL.

2. Place differential case in a soft-jawed vise and remove ring gear-to-case bolts.

Fig. 92: Removing Ring Gear

Courtesy of CHRYSLER GROUP, LLC

3. Remove ring gear from differential case with a brass drift and hammer.
 cardiagn.com
Fig. 93: Pinion Flange Nut Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

4. Using 41mm socket and Flange Wrench (special tool #C-3281, Holder, Flange) (1), remove
pinion nut and discard.

Fig. 94: Removing Pinion Flange With Puller

Courtesy of CHRYSLER GROUP, LLC

5. Using Puller (special tool #1026, Puller) (1), remove pinion flange (2).
 cardiagn.com
Fig. 95: Pinion Seal Removal
Courtesy of CHRYSLER GROUP, LLC

6. Using a suitable screwdriver, remove and discard the pinion seal.

7. Remove pinion tail bearing cone.

Fig. 96: Pressing Pinion Shaft Out Of Carrier

Courtesy of CHRYSLER GROUP, LLC

8. Move axle housing to press and press out pinion shaft (1) as shown in illustration.
 Fig. 97: Washer On Pinion Shaft

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Courtesy of CHRYSLER GROUP, LLC

9. Remove the washer (1).

Fig. 98: Removing Pinion Head Bearing

Courtesy of CHRYSLER GROUP, LLC

10. Remove pinion head bearing (2) with Puller/Press (special tool #C-293-PA, Puller, Press) (1)
and Adapters (special tool #C-293-37, Block Set, Puller) (3, 4).
 cardiagn.com
Fig. 99: Removing Pinion Head Bearing Cup
Courtesy of CHRYSLER GROUP, LLC

11. Using Handle (special tool #C-4171, Driver Handle, Universal) (2) and Remover (special tool
#9084, Remover, Pinion Bearing Cup) (1), drive out pinion head bearing cup.

Fig. 100: Removing/Installing Shim

Courtesy of CHRYSLER GROUP, LLC

12. Remove pinion head shim. Measure and record shim thickness.
 cardiagn.com
Fig. 101: Removing Pinion Tail Bearing Cup
Courtesy of CHRYSLER GROUP, LLC

13. Using Handle (special tool #C-4171, Driver Handle, Universal) (2) and Remover (special tool
#D-149, Remover, Bearing Cup) (1), drive out pinion tail bearing cup.

INSTALLATION

INSTALLATION

Fig. 102: Removing/Installing Shim

Courtesy of CHRYSLER GROUP, LLC

1. Install selected pinion depth shim (1) into housing.

 cardiagn.com
Fig. 103: Pinion Head Bearing Cup Installation
Courtesy of CHRYSLER GROUP, LLC

2. Press pinion head bearing cup into housing using Handle (special tool #C-4171, Driver Handle,
Universal) (1) and Installer (special tool #C-4310, Installer, Bearing) (2).

Fig. 104: Installing Pinion Tail Bearing Cup

Courtesy of CHRYSLER GROUP, LLC

3. Press pinion tail bearing cup into housing using Handle (special tool #C-4171, Driver Handle,
Universal) (1) and Installer (special tool #D-146, Installer, Bearing Cup) (2).
 cardiagn.com
Fig. 105: Installing Pinion Head Bearing
Courtesy of CHRYSLER GROUP, LLC

4. Press new pinion head bearing (2) onto pinion shaft using Installer (special tool #C-3095-A,
Installer, Bearing) (1).
 Fig. 106: Washer On Pinion Shaft

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Courtesy of CHRYSLER GROUP, LLC

5. Install the washer (1).

Fig. 107: Support Pinion Head & Carrier

Courtesy of CHRYSLER GROUP, LLC

6. Install pinion shaft (1) into housing and support on press table atop Installer (special tool #8255,
Installer) (2). Ensure pinion gear face is centered atop Installer (special tool #8255,
Installer).
 cardiagn.com
Fig. 108: Pinion Tail Bearing Installation
Courtesy of CHRYSLER GROUP, LLC

7. Using Installer (special tool #C-3095-A, Installer, Bearing) (1), press on new pinion tail bearing
(2).
 cardiagn.com
Fig. 109: Installing Pinion Seal
Courtesy of CHRYSLER GROUP, LLC

8. Install new pinion seal into position.

9. Press pinion seal into housing using Installer (special tool #9231A, Installer, Pinion Oil Seal) (1).

Fig. 110: Installing Pinion Seal

Courtesy of CHRYSLER GROUP, LLC

10. Lightly lubricate pinion flange seal with axle lubricant for flange installation.
11. Align index marks and press pinion flange (2) on using Installer (special tool #C-3095-A,
Installer, Bearing) (1).
 cardiagn.com
Fig. 111: Torquing Pinion Flange Nut
Courtesy of CHRYSLER GROUP, LLC

12. Install new pinion flange nut by hand.

13. Hold pinion flange with Flange Wrench (special tool #C-3281, Holder, Flange) (1). Using a deep
41 mm socket, tighten pinion flange nut to an initial torque of 203 N.m (150 ft. lbs.).

Fig. 112: Measuring Turning Torque

Courtesy of CHRYSLER GROUP, LLC

14. Rotate pinion flange to ensure bearing is properly seated.

15. Measure pinion rotating torque using suitable torque wrench (1). Pinion rotating torque
should be 215-245 N. cm (19-22 in. lbs.).
16. If pinion rotating torque exceeds the specified range, the pinion shaft must be removed and the
crush sleeve replaced.

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Fig. 113: Torquing Pinion Flange Nut
Courtesy of CHRYSLER GROUP, LLC

17. If pinion rotating torque is below the specified range, increase nut torque by 7 N.m (5 ft. lbs.)
increments and recheck turning torque until rotating torque is within range.

Fig. 114: Staking Pinion Flange Nut

Courtesy of CHRYSLER GROUP, LLC

18. Stake pinion flange nut (1) using hammer and suitable punch.
 Fig. 115: Ring Gear Bolts
Courtesy of CHRYSLER GROUP, LLC

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19. Install ring gear to differential case. Loosely install new ring-gear-to-differential case bolts.
20. Torque all ring gear-to-case bolts to 85 N.m (64 ft. lbs.)

Fig. 116: Removing/Installing Differential

Courtesy of CHRYSLER GROUP, LLC

21. Install differential and reassemble axle assembly. Refer to CASE ASSEMBLY,
DIFFERENTIAL, INSTALLATION.

SEAL, AXLE DRIVE SHAFT

REMOVAL
REMOVAL

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Fig. 117: Remove Lside Seal
Courtesy of CHRYSLER GROUP, LLC

1. Remove halfshaft(s). Refer to REMOVAL and REMOVAL .

2. Using suitable screwdriver (1), remove axle shaft seal (2).
3. Visually inspect halfshaft seal journal for damage (excessive seal groove, nicks, scratches,
etc.). Replace halfshaft if necessary.

INSTALLATION

INSTALLATION
 cardiagn.com
Fig. 118: Axle Seal Installation
Courtesy of CHRYSLER GROUP, LLC

1. Using Installer (special tool #9223A, Drift) (2), install NEW axle shaft seal (1). Lubricate the
inside diameter with Mopar® Gear and Axle Lubricant 75W-140 to protect seal during halfshaft
installation.
2. Install halfshaft(s). Refer to INSTALLATION and INSTALLATION .

Fig. 119: Rear Axle Fill Plug

Courtesy of CHRYSLER GROUP, LLC

3. Remove fill plug (1) to check and adjust rear axle fluid level. Top off axle with Mopar® Gear and
Axle Lubricant 75W-140. Reinstall fill plug torque to 60 N.m (44 ft. lbs.) torque.
SEAL, DRIVE PINION
REMOVAL

REMOVAL

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Fig. 120: Measuring Turning Torque
Courtesy of CHRYSLER GROUP, LLC

1. Remove rear axle assembly from vehicle. Refer to REMOVAL.

2. Measure axle assembly rotating torque and record measurement for reuse on assembly.

Fig. 121: Pinion Flange Nut Removal/Installation

 Courtesy of CHRYSLER GROUP, LLC

3. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1) and 41mm socket, remove
pinion flange nut and discard.

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Fig. 122: Removing Pinion Flange With Puller
Courtesy of CHRYSLER GROUP, LLC

NOTE: Due to axle imbalance concerns, it is necessary to make sure pinion

flange-to-shaft orientation is maintained. If alignment marks are not
visible, apply appropriate marks before removing pinion flange.

4. Using Puller (special tool #1026, Puller) (1), remove pinion flange (2) from pinion shaft.
 Fig. 123: Pinion Seal Removal
Courtesy of CHRYSLER GROUP, LLC

5. Using suitable tool (1), remove pinion seal (2) and discard.

INSTALLATION

INSTALLATION

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Fig. 124: Installing Pinion Seal
Courtesy of CHRYSLER GROUP, LLC

1. Apply light coating of gear lubricant to the lip of the pinion seal.
2. Using Installer (special tool #9231A, Installer, Pinion Oil Seal) (1), install pinion seal until tool
bottoms on carrier.
 cardiagn.com
Fig. 125: Installing Pinion Flange
Courtesy of CHRYSLER GROUP, LLC

3. Install pinion flange into position. Align index marks to maintain assembly balance.
4. Using Installer (special tool #6448A, Installer, Bearing/Gear) (1), lightly tap on pinion flange (2)
until adequate pinion shaft threads are exposed.

Fig. 126: Pinion Flange Nut Removal/Installation

Courtesy of CHRYSLER GROUP, LLC

5. Install new pinion flange nut. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1)
and 41mm socket, torque nut to 136 N.m (100 ft. lbs.).
 cardiagn.com
Fig. 127: Measuring Turning Torque
Courtesy of CHRYSLER GROUP, LLC

6. Measure assembly turning torque. Axle assembly rotating torque should be equal to the reading
recorded upon seal/flange removal.

Fig. 128: Pinion Flange Nut Removal/Installation

Courtesy of CHRYSLER GROUP, LLC

7. If rotating torque is low, increase pinion flange nut torque in 7 N.m (5 ft. lbs.) increments. Repeat
until proper rotating torque is received.
 cardiagn.com
Fig. 129: Staking Pinion Flange Nut
Courtesy of CHRYSLER GROUP, LLC

8. Stake pinion flange nut (1) as shown in illustration.

9. Install rear axle assembly. Refer to INSTALLATION.