DRIVELINE/AXLES

Rear Axle - G648 - Chrysler 300

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - NOISE

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.

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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:

Axle mounts damaged, worn, or bottoming out.

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.

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.

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Loose wheel lug nuts.
Worn U-joints, or CV joints.
Worn rubber coupler between the propeller shaft and the pinion yoke.
Washers missing from the fasteners that attach the rubber coupler to the pinion yoke.
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:

Cradle-to-body isolator worn or damaged.

Worn or damaged rubber washer between axle hub nut and axle hub.
High engine idle speed.
Transmission shift operation.
Loose engine/transmission/transfer case mounts.
Worn U-joints, or CV joints.
Worn rubber coupler between the propeller shaft and the pinion yoke.
Worn or broken axle mount isolators.
 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

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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.
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. Re-adjust bearing pre-load.
4. Insufficient ring gear 4. Re-adjust ring gear
backlash. backlash.
GEAR TEETH BROKE 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

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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.

ADJUSTMENTS
PINION DEPTH

NOTE: Pinion depth measurement is taken with the pinion head and tail bearing cups
pressed into the axle housing without the shim.
Fig. 1: Pinion Bearing Cup Installer

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not attempt to install the inner and outer pinion bearing cups at the same
time.

1. If necessary, install the pinion head bearing cup into housing with Pinion Bearing Cup Installer
(special tool #10148, Installer, Pinion Head Bearing Cup) (1).
2. If necessary, press pinion tail bearing cup into housing with Pinion Bearing Cup Installer
(special tool #10148, Installer, Pinion Head Bearing Cup) (1).

Fig. 2: Arbor Bar

Courtesy of CHRYSLER GROUP, LLC

3. Install Arbor Bar (special tool #10149-2, Arbor) (1) into the case side bearing bore, then secure
Arbor (special tool #10149-2, Arbor) in place with Plate (special tool #10149-5, Washer) and
 fastener.

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Fig. 3: Pinion Head Bearing
Courtesy of CHRYSLER GROUP, LLC

4. Install the pinion head bearing, tail bearing (3), L-block (special tool #6739, Block, Height) (1),
and the Pinion Height Block (special tool #10149-1, Block, Pinion) (2).
5. Verify pinion depth measurement tools are set up as shown in illustration.

Fig. 4: Indicator/Scooter Block Setup

Courtesy of CHRYSLER GROUP, LLC

6. Install Dial Indicator (special tool #9524, Indicator, Dial) (1) to Scooter Block (special tool #D-
115-2A, Block, Scooter) (2). Secure with set-screw (3).
 Fig. 5: Zeroing In Dial Indicator On L-Block

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Courtesy of CHRYSLER GROUP, LLC

7. Zero Dial Indicator (special tool #9524, Indicator, Dial) (1) on L-block (special tool #6739, Block,
Height) (2).

Fig. 6: Slide Indicator Probe Off Of Height Block And Onto Arbor Bar
Courtesy of CHRYSLER GROUP, LLC

8. Slide indicator probe (1) off of height block and onto Arbor Bar (special tool #10149-2, Arbor)
(2). As indicator contacts Arbor Bar (special tool #10149-2, Arbor) (2), indicator needle will
rotate clockwise. Continue moving indicator probe to the crest of Arbor Bar (special tool
#10149-2, Arbor) and record the highest reading.
9. Rotate Arbor Bar (special tool #10149-2, Arbor) (2) 90°.
10. Repeat steps 7 through 9 and record each measurement until the Arbor Bar (special tool
#10149-2, Arbor) has been rotated back to the original location.
11. Average the four measurements taken in steps 7 through 10.
12. Select a shim equal to the average of the measurements, plus 1.5 mm (0.059 in.).

SIDE BEARING PRELOAD ADJUSTMENT

NOTE: Select the pinion shim before performing this procedure.

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Fig. 7: Side Bearing Preload Adjustment
Courtesy of CHRYSLER GROUP, LLC

1. Clean the differential bearing cup bore in the axle housing.

2. Install Dummy Bearing (special tool #10149-3, Dummy Housing Bearing) in the axle housing.
3. Clean the differential bearing cup bore in the axle housing cover.
4. Install Dummy Bearing (special tool #10149-4, Dummy Cover Bearing) in the axle housing
cover.
5. Install the differential into the axle housing.
6. Install the axle housing cover and tighten the bolts to 10 Nm (7 ft. lbs.).
7. Set up the dial indicator (1) to measure endplay on the housing side of the differential (2).
8. From the housing side of the differential, press the differential toward the case cover, then zero
the dial indicator (1).
9. From the case cover side, press the differential toward the housing side, and record the
measurement.
10. Add 1.33 mm (0.052 in.) to the empty case measurement taken in the previous step and record
the results. This is the total dimension of both differential shims when installed.
11. Remove the dial indicator.
12. Remove the axle housing cover.
13. Fully install the pinion.
14. Install the Dummy Bearing (special tool #10149-3, Dummy Housing Bearing) in the axle
housing, then install the differential carrier into the axle housing.
15. Install Dummy Bearing (special tool #10149-4, Dummy Cover Bearing) in the axle housing
cover, and install the axle housing cover. Tighten the bolts to 10 Nm (7 ft. lbs.).
16. Set up the dial indicator (1) as before.
17. From the housing side of the differential, press the differential toward the case cover, then zero
the dial indicator (1).
18. From the case cover side, press the differential toward the housing side, and record the
measurement.
19. Subtract 0.27 mm (0.01 in.) from the measurement found in the previous step 10. This is the
size of the shim that should be installed in the housing cover.
20. Subtract the size of the selected housing cover shim from the measurement found in. This is the
size of the shim that should be installed in the housing.
21. Check ring gear backlash. Final ring gear backlash should be 0.21 mm +/- 0.13 mm (0.008 in.

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+/- 0.005 in.).

Fig. 8: Backlash Shim Correction

Courtesy of CHRYSLER GROUP, LLC

22. If backlash measurement is less than 0.08 mm (0.003 in.), it is necessary to decrease the shim
thickness on the ring gear (left) side, and increase the thickness on the pinion (right) side.
23. If backlash measurement is greater than 0.34 mm (0.013 in.), it is necessary to increase the
shim thickness on the ring gear (right) side, and decrease the thickness on the pinion (left) side.
24. Check the gear contact pattern, and adjust as necessary. Refer to GEAR CONTACT
PATTERN.
GEAR CONTACT PATTERN

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Fig. 9: Gear Tooth Contact Patterns
Courtesy of CHRYSLER GROUP, LLC

NOTE: 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. Install the differential side bearings and pinion bearings.

2. Install the selected differential bearing and pinion shims in the differential housing and cover,
and install the bearing cups.
3. Install the differential carrier and pinion in the differential housing.
4. Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring
gear teeth.
5. Install the differential housing cover. Tighten the bolts to 28 Nm (20 ft. lbs.).
6. Make a witness mark on the differential carrier.
7. Hold the differential case from freely rotating. This will provide a more distinct contact pattern.
8. Rotate the pinion until the witness mark on the differential case has made one complete
revolution in both directions.

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

SPECIFICATIONS
SPECIFICATIONS

AXLE
ITEM DESCRIPTION
Fluid Mopar® Gear and Axle Lubricant 75W-90
MOPAR® Limited Slip Additive Friction
Friction Modifier
Modifier

TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Fill Hole Plug 35 25 -
Drain Hole Plug 35 25 -
Rear Axle Front Mount 65 48 -
Axle-to-Crossmember
220 162 -
Bolts
Pinion Nut 245 180 -
Case Cover Bolts 28 20 -
Ring Gear Bolt Torques 185 136 -
Total Torque to Rotate
2.5 - 6.0 22 - 53 -
(new bearings)
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.

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

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Fig. 10: Drain And Fill Plug
Courtesy of CHRYSLER GROUP, LLC

2. Remove axle drain plug (1) and drain rear axle fluid into suitable container.
3. Install drain plug (1). Do not tighten at this time.
4. Remove the muffler. Refer to MUFFLER, EXHAUST, REMOVAL .
 Fig. 11: Marks On Propeller Shaft Rubber Coupler

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Courtesy of CHRYSLER GROUP, LLC

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

Fig. 12: Propeller Shaft Rear Coupler To Axle Flange

Courtesy of CHRYSLER GROUP, LLC

NOTE: If re-using the propeller shaft coupler-to-axle flange fasteners, save the
washers.

6. Remove three propeller shaft coupler (2) -to-axle flange (1) fasteners.
 Fig. 13: Using Suitable Pry Bar Partially Disengage Halfshaft From Axle Assembly

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not pry on the slinger (2).

7. Using suitable pry bar (1) in the location shown in illustration, partially disengage halfshaft(s)
from axle assembly.

Fig. 14: 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. 15: Front Mount Bolt Cover
Courtesy of CHRYSLER GROUP, LLC

9. Remove the front mount bolt cover (1) located at the top of the axle carrier (2).

Fig. 16: Rear Axle Front Mount

Courtesy of CHRYSLER GROUP, LLC

NOTE: The nut will turn free at the at the top of the axle carrier, it will need to be
held with a deep socket during removal.

10. Remove rear axle front mount bolt (1) and nut (3).
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Fig. 17: Right Rear Bolt
Courtesy of CHRYSLER GROUP, LLC

11. Remove right rear axle-to-crossmember bolts (1).

Fig. 18: Left Rear Bolt

Courtesy of CHRYSLER GROUP, LLC

12. Remove the left rear bolt.

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Fig. 19: Lower Rear End
Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not pry on the axle halfshaft slinger.

13. Carefully lower rear axle. While lowering axle, separate right halfshaft (1) from axle and support
with suitable rope or wire.

Fig. 20: Left Halfshaft

Courtesy of CHRYSLER GROUP, LLC

14. Remove left halfshaft (2).

15. Remove axle assembly from vehicle and transfer to bench.
INSTALLATION
INSTALLATION

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Fig. 21: Left Halfshaft
Courtesy of CHRYSLER GROUP, LLC

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

1. Using new circlip(s), install left halfshaft (2) to rear axle assembly. Do not damage axle seals.
Verify proper installation by pulling outward on joint by hand.
 Fig. 22: Seal Protector
Courtesy of CHRYSLER GROUP, LLC

2. Using (special tool #9099, Seal Protector, Differential Output) (3) install the right halfshaft (1)
into axle (2).

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Fig. 23: Marks On Propeller Shaft Rubber Coupler
Courtesy of CHRYSLER GROUP, LLC

NOTE: To prevent damage or imbalance, washers must be placed on fasteners

that attach rubber coupler to the pinion yoke.

NOTE: To prevent damage or imbalance, washers must be installed between

fastener heads and the rubber coupler.

3. 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. 24: Right Rear Bolt
Courtesy of CHRYSLER GROUP, LLC

NOTE: Clean the rear axle-to-crossmember bolts and apply a patch of blue
MOPAR® Lock & Seal medium strength thread locker to the rear axle-to-
crossmember bolts.

4. Install right rear axle-to-crossmember bolt (1) and tighten to 220 N.m (162 ft. lbs.).

Fig. 25: Left Rear Bolt

 Courtesy of CHRYSLER GROUP, LLC

NOTE: Clean the rear axle-to-crossmember bolts and apply a patch of blue
MOPAR® Lock & Seal medium strength thread locker to the rear axle-to-
crossmember bolts.

5. Install left rear axle-to-crossmember bolt (1) and tighten to 220 N.m (162 ft. lbs.).

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Fig. 26: Rear Axle Front Mount
Courtesy of CHRYSLER GROUP, LLC

NOTE: The rubber part of the axle isolator must face toward the cradle.

6. Install rear axle front mount isolator (3) as shown in illustration and torque fastener to 65 N.m
(48 ft. lbs.).
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Fig. 27: Front Mount Bolt Cover
Courtesy of CHRYSLER GROUP, LLC

7. Install the front mount bolt cover (1).

Fig. 28: 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).
 Fig. 29: Propeller Shaft Rear Coupler To Axle Flange

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Courtesy of CHRYSLER GROUP, LLC

NOTE: If re-using original fasteners, apply a patch of blue MOPAR® Lock & Seal
medium strength thread locker to the propeller shaft coupler-to-axle flange
fasteners. New fasteners have a thread lock patch, and do not require
application of blue MOPAR® Lock & Seal medium strength thread locker.

11. Install the propeller shaft coupler-to-axle flange fasteners. Tighten the propeller shaft coupler-to-
axle flange fasteners (2) to 122 N.m (89 ft. lbs.).

Fig. 30: Drain And Fill Plug

Courtesy of CHRYSLER GROUP, LLC
12. Remove rear axle fill plug (2). Fill axle with 1.2L (1.2 qts.) of Mopar® 75W-90 Synthetic Gear
and Axle Lubricant and add one 0.03 L (4 oz.) bottle of MOPAR® Limited Slip Additive Friction
Modifier. Install fill plug and torque to 35 N.m (25 ft. lbs.).

SPECIAL TOOLS
SPECIAL TOOLS

10146 - Installer, Oil Seal

(Originally Shipped In Kit Number(s) 10145, 10146.)
10147 - Installer, Differential Bearing Cup
(Originally Shipped In Kit Number(s) 10145.)
10148 - Installer, Pinion Head Bearing Cup
(Originally Shipped In Kit Number(s) 10145.)
10149-1 - Block, Pinion

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(Originally Shipped In Kit Number(s) 10145.)
10149-2 - Arbor
(Originally Shipped In Kit Number(s) 10145.)
10149-3 - Dummy Housing Bearing
(Originally Shipped In Kit Number(s) 10145.)
10149-4 - Dummy Cover Bearing
(Originally Shipped In Kit Number(s) 10145.)
10149-5 - Washer
(Originally Shipped In Kit Number(s) 10145.)
1026 - Puller
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC.)
1130 - Splitter, Bearing/Gear
(Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9202, 9202A-CAN, 9202CC,
9299.)
6446 - Installer, Bearing
(Originally Shipped In Kit Number(s) 6440.)
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.)
7794-A - Remover, Seal
(Originally Shipped In Kit Number(s) 6645.)
8915 - Brace
(Originally Shipped In Kit Number(s) 8998, 8998CC, 9763.)
9099 - Seal Protector, Differential Output
(Originally Shipped In Kit Number(s) 9324, 9324CC.)
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.)
9593 - Remover, Bearing Cup
 (Originally Shipped In Kit Number(s) 9692.)
9919 - Installer, Bearing
(Originally Shipped In Kit Number(s) 9870, 9971.)
C-293-3 - Adapter, Bearing/Gear
(Originally Shipped In Kit Number(s) 8418, 8837, C-293-M, C-4246-AL, DD-914-CLT-L.)
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-3281 - Holder, Flange
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)
C-4171 - Driver Handle, Universal
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)

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C-637 - Slide Hammer, Universal
(Originally Shipped In Kit Number(s) 9202.)
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.)

BEARING, DIFFERENTIAL SIDE

REMOVAL

REMOVAL

1. Remove the differential case assembly. Refer to CASE ASSEMBLY, DIFFERENTIAL,

REMOVAL.

Fig. 31: Removing Differential Bearings From Case

 Courtesy of CHRYSLER GROUP, LLC

2. Remove the Differential Bearings from the case with Puller Press (special tool #C-293-PA,
Puller, Press) (1), Bearing/Gear Adapter (special tool #C-293-3, Adapter, Bearing/Gear) (2) and
Adapter Blocks (special tool #C-293-37, Block Set, Puller) (3).

INSTALLATION

INSTALLATION

WARNING: Use tongs or welding gloves when handling heated components. Failure
to follow these instructions will result in personal injury.

CAUTION: Use only a bearing heater/hot plate and follow manufacturer's instructions.
Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit).

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Never use an open flame to heat components. Never leave components on
heater for an extended amount of time. If component is discolored after
heating, the component has been overheated and must not be used.
Failure to follow these instructions will result in component damage.

Fig. 32: Heating Differential Bearings With A Bearing Heater

Courtesy of CHRYSLER GROUP, LLC

1. Heat the Differential Bearings with a bearing heater.

2. Immediately after heating, install the Differential Bearings.

CASE ASSEMBLY, DIFFERENTIAL

REMOVAL
REMOVAL

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Fig. 33: Removing Case Half Bolts
Courtesy of CHRYSLER GROUP, LLC

1. Remove the Rear Axle Assembly. Refer to REMOVAL.

2. Remove the Case Half Bolts (1) and remove the Case Half (2).

Fig. 34: Remove/Install Differential Case

Courtesy of CHRYSLER GROUP, LLC

3. Remove the Differential Case (1).

DISASSEMBLY

DISASSEMBLY
Fig. 35: Ring Gear Bolts

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Courtesy of CHRYSLER GROUP, LLC

1. Remove the ring gear bolts (1) and tap ring gear (2) off of the differential case with a soft faced
hammer.
2. Remove the differential side bearings. Refer to BEARING, DIFFERENTIAL SIDE, REMOVAL.

Fig. 36: Splitting Primary And Secondary Differential Case Halves

Courtesy of CHRYSLER GROUP, LLC

3. Split the primary (1) and secondary (2) differential case halves.
 Fig. 37: Separating Primary And Secondary Differential Case Halves

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Courtesy of CHRYSLER GROUP, LLC

4. Separate the primary (1) and secondary (2) differential case halves.

Fig. 38: Remove/Install Differential Side Gear

Courtesy of CHRYSLER GROUP, LLC

5. Remove the differential side gear (1).

 Fig. 39: Remove/Install Clutch Pack & Belleville Spring

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Courtesy of CHRYSLER GROUP, LLC

6. Remove the clutch pack (1) and the Belleville spring (2).

Fig. 40: Remove/Install Primary Differential Pinion Gear Shaft

Courtesy of CHRYSLER GROUP, LLC

NOTE: It may be necessary use the differential side gear to press downward on
the four pinions (2) for primary differential pinion gear shaft (1) removal.

7. Remove the primary differential pinion gear shaft (1).

 Fig. 41: Remove/Install Primary Differential Pinion Gears

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Courtesy of CHRYSLER GROUP, LLC

8. Remove the primary differential pinion gears (1).

Fig. 42: Secondary Differential Side Gears

Courtesy of CHRYSLER GROUP, LLC

9. Use a brass drift to tap the secondary (split) pinion shafts (1) out of the differential case, then
remove the secondary differential side gears (2).
 Fig. 43: Remove/Install Differential Side Gear

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Courtesy of CHRYSLER GROUP, LLC

10. Remove the differential side gear (1) from the primary differential case half (2).

Fig. 44: Identifying Clutch Pack, Belleville Spring & Primary Differential Case Half
Courtesy of CHRYSLER GROUP, LLC

11. Remove the clutch pack (1) and the Belleville spring (2) from the primary differential case half
(3).

ASSEMBLY

ASSEMBLY
Fig. 45: Clutch Pack

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Courtesy of CHRYSLER GROUP, LLC

1. Assemble the clutch pack as follows: Friction disc (1), tabbed plate (2), friction disc (3), tabbed
plate (4), large friction disc (5), and Belleville spring (6). Verify the friction surface on the large
friction disc (5) is facing the tabbed plate (4).

Fig. 46: Identifying Clutch Pack, Belleville Spring & Primary Differential Case Half
Courtesy of CHRYSLER GROUP, LLC

NOTE: Verify the raised edge of the Belleville spring (2) is facing up, or away from
the clutch pack (1).

2. Install the clutch pack (1) and the Belleville spring (2) into the primary differential case half (3).
 Fig. 47: Remove/Install Differential Side Gear

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Courtesy of CHRYSLER GROUP, LLC

3. Install the differential side gear (1) into the primary differential case half (2).

Fig. 48: Splines On Differential Side Gear

Courtesy of CHRYSLER GROUP, LLC

4. Verify the differential side gear (1) is fully seated in the primary case half (2). Rotate the side
gear as necessary to align the splines on all the friction plates with the splines on the differential
side gear (1).
 Fig. 49: Secondary Differential Side Gears

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Courtesy of CHRYSLER GROUP, LLC

5. Install the secondary differential side gears (2), then slightly compress the Belleville spring by
pressing down on the differential side gear, and install the secondary (split) pinion shafts (1).

Fig. 50: Remove/Install Primary Differential Pinion Gears

Courtesy of CHRYSLER GROUP, LLC

6. Install the primary differential pinion gears (1).

 Fig. 51: Remove/Install Primary Differential Pinion Gear Shaft

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Courtesy of CHRYSLER GROUP, LLC

NOTE: It may be necessary use the differential side gear to press downward on
the four pinions (2) for primary differential pinion gear shaft (1) removal.

7. Install the primary differential pinion gear shaft (1).

Fig. 52: Clutch Pack

Courtesy of CHRYSLER GROUP, LLC

8. Assemble the clutch pack as follows: Friction disc (1), tabbed plate (2), friction disc (3), tabbed
plate (4), large friction disc (5), and Belleville spring (6). Verify the friction surface on the large
friction disc (5) is facing the tabbed plate (4).
 Fig. 53: Remove/Install Clutch Pack & Belleville Spring

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Verify the raised edge of the Belleville spring (2) is facing up, or away from
the clutch pack (1).

9. Install the clutch pack (1) and the Belleville spring (2).

Fig. 54: Remove/Install Differential Side Gear

Courtesy of CHRYSLER GROUP, LLC

10. Install the differential side gear (1).

 Fig. 55: Separating Primary And Secondary Differential Case Halves

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Courtesy of CHRYSLER GROUP, LLC

11. Assemble the primary (1) and secondary (2) differential case halves.

Fig. 56: Ring Gear Bolts

Courtesy of CHRYSLER GROUP, LLC

12. Install the Ring Gear (2), and the Ring Gear Bolts (1). Tighten the ring gear bolts to 185 Nm
(136 ft. lbs.).

INSTALLATION

INSTALLATION
Fig. 57: Remove/Install Differential Case

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Courtesy of CHRYSLER GROUP, LLC

1. Apply a light coat of gear lubricant to differential bearings and bearing cups.
2. Install the Differential Case (1).

Fig. 58: Removing Case Half Bolts

Courtesy of CHRYSLER GROUP, LLC

3. Install the Case Half (2) and the Case Half Bolts (1).
4. Verify the turning torque and differential bearing preload are within acceptable limits. If the
turning torque and differential bearing preload measurements are not within specifications, or if
a new ring and pinion gear have been installed, perform the pinion depth adjustment and
differential side bearing preload and backlash adjustment procedures. Refer to
ADJUSTMENTS.
5. Install the Rear Axle Assembly. Refer to INSTALLATION.
GEAR, RING AND PINION
REMOVAL

REMOVAL

1. Remove the Rear Axle Assembly. Refer to REMOVAL.

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Fig. 59: Removing Case Half Bolts
Courtesy of CHRYSLER GROUP, LLC

2. Remove the Case Half Bolts (1) and remove the Case Half (2).

Fig. 60: Remove/Install Differential Case

Courtesy of CHRYSLER GROUP, LLC
3. Remove the Differential Case (1).

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Fig. 61: Ring Gear Bolts
Courtesy of CHRYSLER GROUP, LLC

4. Remove the Ring Gear Bolts (1) and tap Ring Gear (2) off of the Differential Case with a dead-
blow hammer.

Fig. 62: Remove/Install Pinion Flange

Courtesy of CHRYSLER GROUP, LLC

5. Hold Pinion Flange (2) with Flange Holder (special tool #C-3281, Holder, Flange) (1) and
remove the Pinion Nut.
 Fig. 63: Removing Pinion Flange From Pinion Shaft Using Puller

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Courtesy of CHRYSLER GROUP, LLC

6. Use Puller (special tool #1026, Puller) (1) to remove the Pinion Flange (2) from the Pinion Shaft.

Fig. 64: Pressing Pinion Out Of Case With Arbor Press

Courtesy of CHRYSLER GROUP, LLC

7. Press the Pinion (1) out of the Case (2) with an arbor press.
 Fig. 65: Using Arbor Press And Bearing Splitter To Press Bearing Off Of Pinion

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Tighten Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) enough
so that it does not slip off the bearing during removal

8. Use an arbor press and Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) (2) to press
the Bearing (1) off of the Pinion (3).

Fig. 66: Removing Pinion Bearing Cup By Tapping It Out Through Pinion Shaft Bore
Courtesy of CHRYSLER GROUP, LLC

NOTE: Use a brass drift only. Otherwise, damage can occur.

9. Remove the Pinion Bearing Cup by tapping it out through the Pinion Shaft Bore (1).
 Fig. 67: Removing Pinion Bearing Seal With Slide Hammer And Collet

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Courtesy of CHRYSLER GROUP, LLC

10. Remove the Pinion Bearing Seal with Slide Hammer (special tool #C-637, Slide Hammer,
Universal) and Collet (special tool #7794-A, Remover, Seal).
11. Remove the Outer Pinion Bearing.

Fig. 68: Using Brace And Bearing Remover To Remove Outer Pinion Cup
Courtesy of CHRYSLER GROUP, LLC

12. Use Brace (special tool #8915, Brace) and Bearing Remover (special tool #9593, Remover,
Bearing Cup) to remove the Outer Pinion Cup.
 Fig. 69: Using Bearing Cup Remover And Brace To Remove Differential Bearing Cone

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From Case
Courtesy of CHRYSLER GROUP, LLC

13. Use Bearing Cup Remover (special tool #9593, Remover, Bearing Cup) (1) and Brace (special
tool #8915, Brace) (2) to remove the Differential Bearing Cone (3) from the Case.

Fig. 70: Removing Differential Bearing Cone From Cover

Courtesy of CHRYSLER GROUP, LLC

14. Use Bearing Cup Remover (special tool #9593, Remover, Bearing Cup) (1) and Brace (special
tool #8915, Brace) (2) to remove the Differential Bearing Cone (3) from the Cover.

INSTALLATION

INSTALLATION
Fig. 71: Pinion Bearing Cup Installer

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Do not attempt to install the inner and outer pinion bearing cups at the same
time.

1. Use Pinion Bearing Cup Installer (special tool #10148, Installer, Pinion Head Bearing Cup) (1)
to install the pinion head bearing cup (2).
2. Install the pinion tail bearing cup with pinion bearing cup Installer (special tool #10148, Installer,
Pinion Head Bearing Cup) (1).

Fig. 72: Pinion Depth Shim Onto Pinion Shaft

Courtesy of CHRYSLER GROUP, LLC

3. Determine the correct pinion depth and differential bearing preload. Refer to ADJUSTMENTS.
4. Install the pinion depth shim (1) onto the pinion shaft (2).

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Fig. 73: Pinion Head Bearing
Courtesy of CHRYSLER GROUP, LLC

5. Use an arbor press and Installer (special tool #6446, Installer, Bearing) (1) to install the pinion
head bearing (2).

Fig. 74: Spacer On Pinion Shaft

Courtesy of CHRYSLER GROUP, LLC

6. Install the spacer (1) onto the pinion shaft.

7. Install the pinion into the case.
 cardiagn.com
Fig. 75: Bearing Heater
Courtesy of CHRYSLER GROUP, LLC

WARNING: Use tongs or welding gloves when handling heated components.

Failure to follow these instructions will result in personal injury.

CAUTION: Bearings (1) are installed using a Bearing Heater (2). Use only a
bearing heater/hot plate and follow manufacturer's instructions. Heat
components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit).
Never use an open flame to heat components. Never leave
components on heater for an extended amount of time. If component
is discolored after heating, the component has been overheated and
must not be used. Failure to follow these instructions will result in
component damage.

8. Heat pinion tail bearing (1) to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install on
pinion with tongs or welding gloves.
 Fig. 76: Using Pinion Oil Seal Installer To Install Pinion Seal

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Apply a light coating of gear lube to pinion seal.

NOTE: Allow the pinion tail bearing to cool off to room temperature before
installing the pinion seal.

9. Use pinion oil seal installer (special tool #10146, Installer, Oil Seal) (1) to install the pinion seal
(2).

Fig. 77: Remove/Install Pinion Flange

Courtesy of CHRYSLER GROUP, LLC

10. Install the pinion flange (2).

11. Install the original pinion nut. Hold the pinion flange with flange holder (special tool #C-3281,
Holder, Flange) (1) and tighten the pinion nut.
12. Remove and discard the original Pinion Nut.
13. Remove the Pinion Flange.
14. Install the pinion flange (2) and a new pinion flange nut. Tighten the pinion flange nut to 245 Nm
(180 ft. lbs.).
15. Use an inch pound torque wrench to measure the turning torque of the pinion.
16. If the turning torque is too high, remove the selected shim, and install a larger shim on the
pinion shaft, then verify the turning torque is correct. If the turning torque is too low, remove the
selected shim, and install a smaller shim on the pinion, then verify the turning torque is correct.

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Fig. 78: Ring Gear Bolts
Courtesy of CHRYSLER GROUP, LLC

17. Install the Ring Gear (2), and new Ring Gear Bolts (1). Tighten the bolts to 185 Nm (136 ft. lb.).
 Fig. 79: Shim In Cover

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18. Measure end play of the differential, and determine the size of the required differential shims to
get the correct differential side bearing preload and ring gear backlash. Refer to
ADJUSTMENTS.
19. Install shim (1) in the cover.

Fig. 80: Installing Differential Side Bearing Cup

Courtesy of CHRYSLER GROUP, LLC

20. Use Differential Bearing Cup Installer (special tool #10147, Installer, Differential Bearing Cup)
(2) and Universal Installer Handle (special tool #C-4171, Driver Handle, Universal) (1) to install
the differential side bearing cup (3) into the cover (3).
 Fig. 81: Shim In Case

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Courtesy of CHRYSLER GROUP, LLC

21. Install shim (1) in the case.

Fig. 82: Installing Differential Side Bearing Cup In Case

Courtesy of CHRYSLER GROUP, LLC

22. Use Differential Bearing Cup Installer (special tool #10147, Installer, Differential Bearing Cup)
and Universal Installer Handle (special tool #C-4171, Driver Handle, Universal) to install the
Differential Side Bearing Cup into the Case.
23. Install the Differential in the housing.
 Fig. 83: Removing Case Half Bolts

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Courtesy of CHRYSLER GROUP, LLC

24. Temporarily install the cover (2), and the cover bolts (1).
25. Verify the ring and pinion gear contact pattern is within acceptable limits.
26. Tighten the cover bolts to 28 Nm (20 ft. lbs.).
27. Verify the total turning torque of the differential is within 2.5 to 6.0 Nm (22 - 53 in. lbs.). If
necessary, adjust the size of the differential shims to bring the turning torque within
specifications.
28. Install the rear axle assembly. Refer to INSTALLATION.

SEAL, AXLE DRIVE SHAFT

REMOVAL

REMOVAL
 cardiagn.com
Fig. 84: Remove L Side 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. 85: Install R Side Seal
Courtesy of CHRYSLER GROUP, LLC

1. Using Installer (special tool #9919, Installer, Bearing) (2) and Handle (special tool #C-4171,
Driver Handle, Universal) (3), install NEW axle shaft seal (1). Lubricate the inside diameter with
Mopar® Gear and Axle Lubricant 75W-90 to protect seal during halfshaft installation.
2. Install halfshaft(s). Refer to INSTALLATION and INSTALLATION .

Fig. 86: Drain And Fill Plug

 Courtesy of CHRYSLER GROUP, LLC

3. Remove fill plug (2) to check and adjust rear axle fluid level. Top off axle with Mopar® Gear and
Axle Lubricant 75W-90. Reinstall fill plug and torque to 35 N.m (25 ft. lbs.) torque.

SEAL, DRIVE PINION

REMOVAL

REMOVAL

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

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Fig. 87: Using A Torque Wrench Calibrated To Measure Low Torque Values
Courtesy of CHRYSLER GROUP, LLC

2. Use a torque wrench calibrated to measure low torque values (1) to measure rotating torque at
the pinion flange (2). Record measurement for reuse on assembly.
 cardiagn.com
Fig. 88: 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.

Fig. 89: 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.

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Fig. 90: Removing Pinion Seal Using A Suitable Seal Removal Tool
Courtesy of CHRYSLER GROUP, LLC

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

INSTALLATION

INSTALLATION

1. Apply light coating of gear lubricant to the lip of the pinion seal.

Fig. 91: Installing Pinion Seal Until Tool Bottoms On Carrier Using Installer
Courtesy of CHRYSLER GROUP, LLC
2. Using Installer (special tool #10146, Installer, Oil Seal) (1), install pinion seal until tool bottoms
on carrier.

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Fig. 92: Pinion Flange Installation
Courtesy of CHRYSLER GROUP, LLC

3. Install pinion flange into position. Align index marks made during disassembly to maintain
assembly balance.
4. Using Installer (special tool #6448A, Installer, Bearing/Gear) (1), lightly tap on pinion flange (2)
until enough pinion shaft threads are exposed to install the pinion flange, and start the pinion
nut.

Fig. 93: Pinion Flange Nut Removal/Installation

 Courtesy of CHRYSLER GROUP, LLC

5. Install a new pinion flange nut. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1)
and 41mm socket, torque nut to 245 N.m (181 ft. lbs.).

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Fig. 94: Using A Torque Wrench Calibrated To Measure Low Torque Values
Courtesy of CHRYSLER GROUP, LLC

6. Use a torque wrench calibrated to measure low torque values (1) to measure rotating torque at
the pinion flange (2). Verify the turning torque matches the rotating torque as measured before
removal of the original seal.

Fig. 95: Pinion Flange Nut Removal/Installation

Courtesy of CHRYSLER GROUP, LLC
7. Install rear axle assembly. Refer to Rear Axle INSTALLATION .

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