Chrysler Full-Size Trucks 1989-1996 Repair Guide

Pinion Seal

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REMOVAL & INSTALLATION 1 / 4 and 8 1 / 4 In. Axles



Chrysler 7

See Figures 1, 2, 3 and 4

  1. Raise the vehicle and support safely.
  2.  
  3. Matchmark and remove the driveshaft.
  4.  
  5. Remove the rear wheel and brake drums to prevent any drag.
  6.  
  7. Using an inch lb. torque wrench, measure the pinion bearing preload. Read the torque while the handle of the wrench is moving through several complete revolutions.
  8.  



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Fig. Fig. 1: Check the pinion bearing preload as shown



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Fig. Fig. 2: Remove the drive pinion flange as shown

  1. Using the proper tools, hold the companion flange and remove the drive pinion nut and washer.
  2.  
  3. Remove the companion flange. Lower the rear of the vehicle to prevent fluid loss.
  4.  
  5. Using a seal remover tool, remove the seal from the carrier and clean the seal seat.
  6.  

To install:
  1. The outside diameter of the seal is pre-coated with a special sealer so no sealing compound is required for installing. The seal is properly installed when the flange contacts the housing flange face.
  2.  



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Fig. Fig. 3: Use a hammer and an installer tool to drive the pinion seal into place



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Fig. Fig. 4: Tighten the drive pinion nut as shown

  1. Install the companion flange and the washer with the convex side out.
  2.  
  3. Tighten the pinion nut to 210 ft. lbs. (285 Nm) and check the pinion bearing preload. If the preload is less than the original preload measured, continue tightening the nut in very small increments until the proper preload is reached.
  4.  
  5. Install the driveshaft, drums and rear wheels.
  6.  
  7. Refill the differential with the proper lubricant.
  8.  
  9. Road test the vehicle and check for leaks.
  10.  

Chrysler 83/8In. and 91/4In. Axles

An inch pound torque wrench and a torque wrench capable of at least 250 ft. lbs. (340 Nm) are required for pinion seal installation.

  1. Raise and safely support the vehicle with jackstands under the frame rails. Allow the axle to drop to rebound position for working clearance.
  2.  
  3. Remove the rear wheels and brake drums. No drag must be present on the the axle.
  4.  
  5. Mark the companion flanges and U-joints for correct reinstallation position.
  6.  
  7. Remove the driveshaft.
  8.  
  9. Using an inch pound torque wrench and socket on the pinion yoke nut, measure the amount of torque needed to maintain differential rotation through several clockwise revolutions. Record the measurement.
  10.  
  11. Use a suitable tool to hold the companion flange. Remove the pinion nut and washer.
  12.  
  13. Place a drain pan under the differential, clean the area around the seal, and mark the yoke-to-pinion relations.
  14.  
  15. Use a 2-jawed puller to remove the pinion.
  16.  
  17. Remove the seal with a small prybar.
  18.  
  19. Thoroughly clean the oil seal bore.
  20.  

If you are not absolutely certain of the proper seal installation depth, the proper seal driver must be used. If the seal is misaligned or damaged during installation, it must be removed and a new seal installed.

  1. Drive the new seal into place with a seal driver. Coat the seal lip with clean, waterproof wheel bearing grease.
  2.  
  3. Coat the splines with a small amount of wheel bearing grease and install the yoke, aligning the matchmarks. Never hammer the yoke onto the pinion!
  4.  
  5. Install a NEW nut on the pinion.
  6.  
  7. Hold the yoke with a holding tool. Tighten the pinion nut to 210 ft. lbs. (285 Nm). Using the inch pound torque wrench, take several readings. Continue tightening the nut until the original recorded preload reading is achieved.
  8.  

Under no circumstances should the preload be more than 5 inch lbs. (0.6 Nm) higher than the original reading.

  1. Bearing preload should be uniform through several complete revolutions. If binding exists, the condition must be diagnosed and corrected. The assembly is unacceptable if the final pinion nut torque is below 210 ft. lbs. (285 Nm) or pinion bearing preload is not correct.
  2.  


WARNING
Under no circumstances should the nut be backed off to reduced the preload reading!If the preload is exceeded, the yoke and bearing must be removed and a new collapsible spacer must be installed. The entire process of preload adjustment must be repeated.

  1. Install the driveshaft using the matchmarks. Tighten the nuts to 15 ft. lbs. (20 Nm).
  2.  

Model 60 and 70 Axles

A torque wrench capable of at least 300 ft. lbs. (408 Nm) is required for pinion seal installation.

  1. Raise and support the truck on jackstands.
  2.  
  3. Allow the axle to hang freely.
  4.  
  5. Matchmark and disconnect the driveshaft from the front axle.
  6.  
  7. Using a holding tool, holding the pinion flange while removing the pinion nut.
  8.  
  9. Using a puller, remove the pinion flange.
  10.  
  11. Use a puller to remove the seal, or punch the seal out using a pin punch.
  12.  
  13. Thoroughly clean the seal bore and make sure that it is not damaged in any way. Coat the sealing edge of the new seal with a small amount of 80W/90 oil and drive the seal into the housing using a seal driver.
  14.  
  15. Coat the inside of the pinion flange with clean 80W/90 oil and and install the flange onto the pinion shaft.
  16.  
  17. Install the nut on the pinion shaft and tighten it to 250-300 ft. lbs. (340-408 Nm).
  18.  
  19. Connect the driveshaft.
  20.  

 
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