Chrysler Full-Size Trucks 1997-2000 Repair Guide

Pinion Seal

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REMOVAL & INSTALLATION



  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Scribe a mark on the universal joint, pinion yoke, and pinion shaft for installation reference.
  4.  
  5. Disconnect the driveshaft from the pinion yoke.
  6.  
  7. Secure the driveshaft in an upright position to prevent damage to the rear universal joint.
  8.  
  9. Remove the wheel and tire assemblies.
  10.  
  11. Remove the brake drums to prevent any drag. The drag may cause a false bearing rotating torque measurement.
  12.  
  13. Rotate the pinion yoke three or four times.
  14.  
  15. Measure the amount of torque necessary to rotate the pinion gear with a inch pound dial-type torque wrench. Record the torque reading for installation reference.
  16.  
  17. Hold the yoke in position with a pipe wrench or other suitable tool. Remove the pinion shaft nut and washer. Note that the convex side of the washer faces outward. It must be installed the same way.
  18.  
  19. Remove the yoke. A puller will probably be needed.
  20.  
  21. Remove the pinion shaft seal with suitable prytool or slide-hammer mounted screw.
  22.  

To install:

  1. Clean the seal contact surface in the housing bore.
  2.  
  3. Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft.
  4.  
  5. Inspect pinion yoke for cracks, worn splines and worn seal contact surface. Replace yoke if necessary.
  6.  


NOTE
The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required.

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install the new pinion shaft seal. A large socket can be used.
  4.  


NOTE
The seal is correctly installed when the seal flange contacts the face of the differential housing flange.

  1. Position the pinion yoke on the end of the shaft with the reference marks aligned.
  2.  
  3. Seat the yoke on the pinion shaft.
  4.  
  5. Install the pinion yoke washer. The convex side of the washer must face outward.
  6.  


WARNING
Do NOT exceed the minimum tightening torque when installing the pinion yoke retaining nut at this point. Damage to the collapsible spacer or bearings may result.

  1. Hold the pinion yoke with pipe wrench or other suitable tool and tighten shaft nut to 210 ft. lbs. (285 Nm).
  2.  
  3. Rotate the pinion shaft several revolutions to ensure the bearing rollers are seated.
  4.  
  5. Rotate the pinion shaft, using an inch-pounds beam type torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 5 inch lbs. (0.56 Nm). If too low, tighten the pinion shaft nut in 5 ft. lb. (6.8 Nm) increments until the proper torque is achieved.
  6.  


WARNING
Never loosen the pinion gear nut to decrease pinion gear bearing rotating torque, and never exceed the specified preload torque. If preload torque is exceeded, a new collapsible spacer must be installed.

  1. Install the brake drums.
  2.  
  3. Install the wheel and tire assemblies.
  4.  
  5. Align the driveshaft with the pinion yoke and install.
  6.  
  7. Lower the vehicle.
  8.  



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Fig. Always measure bearing preload prior to loosening the pinion nut



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Fig. Pinion shaft nut (arrow)



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Fig. Remove the yoke with a sturdy puller



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Fig. Removing the pinion seal



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Fig. Installing a new pinion seal with a large socket



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Fig. The convex side of the yoke washer must face outward



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Fig. Hold the pinion yoke with a suitable tool and tighten the shaft nut, then recheck the pinion preload

 
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