Cherokee, Grand Cherokee, 1999-2005

Pinion Seal

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Removal & Installation




NOTE
The ring and pinion gears are service in a matched set. Do not replace the pinion gear without replacing the ring gear.

  1. Remove differential assembly from axle housing.
  2.  
  3. Mark pinion yoke and propeller shaft for installation alignment.
  4.  
  5. Disconnect propeller shaft from pinion yoke. Using suitable wire, tie propeller shaft to underbody.
  6.  
  7. Using Holder 6958 to hold yoke and a short length of 1 in. pipe, remove the pinion yoke nut and washer.
  8.  
  9. Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft.
  10.  
  11. Remove the pinion gear from housing. Catch the pinion with your hand to prevent it from falling and being damaged
  12.  
  13. Remove the pinion seal with a slide hammer or pry out with bar.
  14.  
  15. Remove oil slinger, if equipped, and the front pinion bearing.
  16.  
  17. Remove the front pinion bearing cup with Remover D-103 and Handle C-4171.
  18.  
  19. Remove the rear bearing cup from housing. Use Remover C-4307 and Handle C-4171
  20.  
  21. Remove the collapsible preload spacer.
  22.  
  23. Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-42.
  24.  
  25. Place 4 adapter blocks so they do not damage the bearing cage.
  26.  
  27. Remove the pinion depth shims from the pinion gear shaft. Record the total thickness of the depth shims.
  28.  

To install:

  1. Apply Mopar® Door Ease stick lubricant to outside surface of bearing cup.
  2.  
  3. Install the pinion rear bearing cup with Installer C-4308 and Driver Handle C-4171. Ensure cup is correctly seated
  4.  
  5. Apply Mopar® Door Ease stick lubricant to outside surface of bearing cup.
  6.  
  7. Install the pinion front bearing cup with Installer D-129 and Handle C-4171
  8.  
  9. Install pinion front bearing and oil slinger, if equipped. Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171.
    NOTE
    Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement or adjustment.

  10.  
  11. Place the proper thickness pinion depth shim on the pinion gear.
  12.  
  13. Install the rear bearing (and slinger if used) on the pinion gear with Installer 6448.
  14.  
  15. Install a new collapsible preload spacer on pinion shaft.
  16.  
  17. Install pinion gear in housing
  18.  
  19. Install yoke with Installer C-3718 and holder 6958.
  20.  
  21. Install the yoke washer and a new nut on the pinion gear. Tighten the nut to 220 ft. lbs. (289 Nm) minimum. Do not over-tighten. Maximum torque is 280 ft. lbs. (380 Nm).
    CAUTION
    Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will have to be repeated.


    NOTE
    If the spacer requires more than 280 ft. lbs. torque to crush, the collapsible spacer is defective.

  22.  
  23. Using yoke holder 6958, a short length of 1 in. pipe, and a torque wrench set at 280 ft. lbs. (380 Nm), crush collapsible spacer until bearing end play is taken up.
  24.  
  25. Slowly tighten the nut in 5 ft. lbs. (6.8 Nm) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.
  26.  
  27. Rotate the pinion a minimum of ten times. Make sure that the pinion rotates smoothly. Check bearing rotating torque with an inch pound torque wrench. The torque necessary to rotate the pinion gear should be:

    Original Bearings - 10 to 20 in. lbs. (1 to 3 Nm)
     
    New Bearings - 20 to 40 in. lbs. (2.26 to 4.52 Nm)
     

  28.  
  29. Align previously made marks on yoke and propeller shaft and install propeller shaft.
  30.  
  31. Install differential housing into the axle housing.
  32.  

  1. Raise and support the vehicle.
  2.  
  3. Position a lifting device under the axle and secure axle.
  4.  
  5. Remove the wheels and tires.
  6.  
  7. Remove brake calipers and rotors.
  8.  
  9. Disconnect parking brake cables from brackets and lever.
  10.  
  11. Remove wheel speed sensors.
  12.  
  13. Remove brake hose at the axle junction block. Do not disconnect the brake hydraulic lines at the calipers.
  14.  
  15. Disconnect the vent hose from the axle shaft tube.
  16.  
  17. Mark propeller shaft and yokes for installation reference.
  18.  
  19. Remove propeller shaft.
  20.  
  21. Disconnect stabilizer bar links.
  22.  
  23. Remove upper suspension arm rear axle ball joint nut.
  24.  
  25. Separate rear axle ball joint from the upper suspension arm with Remover 8278
  26.  
  27. Disconnect shock absorbers from axle.
  28.  
  29. Disconnect track bar.
  30.  
  31. Disconnect lower suspension arms from the axle brackets.
  32.  
  33. Separate the axle from the vehicle.
  34.  

To install:


CAUTION
The weight of the vehicle must be supported by the springs before suspension arms and track bar fasteners are tightened. If springs are not at their normal ride position, vehicle ride height and handling could be affected.

  1. Raise axle with lift and align coil springs.
  2.  
  3. Install lower suspension arms in axle brackets. Install nuts and bolts, do not tighten bolts at this time.
  4.  
  5. Install upper suspension arm on rear axle ball joint.
  6.  
  7. Install rear axle ball joint nut and tighten to 90 ft. lbs. (122 Nm).
  8.  
  9. Install track bar and attachment bolts, do not tighten bolts at this time.
  10.  
  11. Install shock absorbers and tighten nuts to 44 ft. lbs. (60 Nm).
  12.  
  13. Install stabilizer bar links and tighten nuts to 27 ft. lbs. (36 Nm).
  14.  
  15. Install wheel speed sensors.
  16.  
  17. Connect parking brake cable to brackets and lever.
  18.  
  19. Install brake rotors and calipers.
  20.  
  21. Install the brake hose to the axle junction block.
  22.  
  23. Install axle vent hose.
  24.  
  25. Align propeller shaft and pinion yoke reference marks. Install U-joint straps and nuts tighten to 14 ft. lbs. (19 Nm).
  26.  
  27. Install the wheels and tires.
  28.  
  29. Add gear lubricant, if necessary.
  30.  
  31. Remove support and lower the vehicle.
  32.  
  33. Tighten lower suspension arm bolts to 130 ft. lbs. (177 Nm).
  34.  
  35. Tighten track bar bolts to 74 ft. lbs. (100 Nm).
  36.  

C-Clip Type
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake drums
     
    Driveshaft
     

  4.  
  5. Check the bearing preload with an inch lb. torque wrench.
  6.  
  7. Remove the pinion flange and seal.
  8.  

To install:


NOTE
Use a new pinion nut for assembly.

  1. Install the new pinion seal and flange. Tighten the nut to 200 ft. lbs. (271 Nm).
  2.  
  3. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch lbs.
  4.  
  5. If the preload torque is low, tighten the pinion nut in 5 inch lb. increments until the torque value is reached. Do not exceed 350 ft. lbs. (474 Nm) pinion nut torque.
  6.  
  7. If the pinion bearing preload torque cannot be attained at maximum pinion nut torque, replace the collapsible spacer.
  8.  
  9. Install or connect the following:

    Driveshaft
     
    Brake drums
     
    Wheels
     

  10.  
  11. Fill the axle assembly with gear oil and check for leaks.

    Click image to see an enlarged view

    Fig. Companion shaft puller-C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Tightening the pinion nut-C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Pinion seal installer-C-Clip Type Axle



    Click image to see an enlarged view

    Fig. Measuring pinion rotating torque-C-Clip Type Axle

  12.  

Non C-Clip Type
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Wheels
     
    Brake rotors or drums
     
    Driveshaft
     

  4.  
  5. Check the bearing preload with an inch lb. torque wrench.
  6.  
  7. Remove the pinion flange and seal.
  8.  

To install:


NOTE
Use a new pinion nut for assembly.

  1. Install the new pinion seal and flange. Tighten the nut to 160 ft. lbs. (217 Nm).
  2.  
  3. Check the bearing preload. The bearing preload should be equal to the reading taken earlier, plus 5 inch lbs.
  4.  
  5. If the preload torque is low, tighten the pinion nut in 5 inch lb. increments until the torque value is reached. Do not exceed 260 ft. lbs. (353 Nm) pinion nut torque.
  6.  
  7. If the pinion bearing preload torque can not be attained at maximum pinion nut torque, remove one or more pinion preload shims.
  8.  
  9. Install or connect the following:

    Driveshaft
     
    Brake rotors or drums
     
    Wheels
     

  10.  
  11. Fill the axle assembly with gear oil and check for leaks.
  12.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. With vehicle in neutral, position vehicle on hoist.
  4.  
  5. Mark a reference line across the axle flange and propeller shaft flange.
  6.  
  7. Remove propeller shaft
  8.  
  9. Remove brake calipers and rotors to prevent any drag.
  10.  
  11. Rotate flange three or four times and verify flange rotates smoothly.
  12.  
  13. Measure torque to rotating pinion flange with an inch pound torque wrench. Record the reading for installation reference.
  14.  
  15. Hold pinion flange with Wrench C-3281 and remove pinion nut and washer.
  16.  
  17. Remove flange with two jaw puller.
  18.  
  19. Remove pinion seal with a seal pick or slide-hammer mounted screw.
  20.  

To install:

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install new pinion seal with Installer C-3972A and Handle C-4171.
  4.  
  5. Install flange on the end of the shaft with the reference marks aligned.
  6.  
  7. Install flange on pinion shaft with Installer C-3718 and Wrench C-3281.
  8.  
  9. Install pinion washer and a new pinion nut. The convex side of the washer must face outward.
    WARNING
    Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Failure to follow these instructions can damage the collapsible spacer or bearings.

  10.  
  11. Hold flange with Wrench C-3281 and tighten pinion nut to 210 ft. lbs. (285 Nm). Rotate pinion several revolutions to ensure bearing rollers are seated.
  12.  
  13. Rotate pinion flange with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 5 inch lbs. (0.56 Nm).
    WARNING
    Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions can damage the collapsible spacer or bearings.

  14.  
  15. If rotating torque is low use hold the flange and tighten pinion nut in 60 inch lbs. (6.8 Nm) increments until proper rotating torque is achieved.
    NOTE
    The seal replacement is unacceptable if final pinion nut torque is less than 210 ft. lbs. (285 Nm).


    NOTE
    The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition.

  16.  
  17. Install propeller shaft.
  18.  
  19. Install rear brake components.
  20.  

 
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