Chrysler Full-Size Vans 1967-1988 Repair Guide

Pinion Seal

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REMOVAL & INSTALLATION



Chrysler 8 3 / 4 " Axle

An inch-pound torque wrench and a torque wrench capable of at least 200 ft. lbs. 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 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 relation.
  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 ip 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 100 ft. lbs. 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 in. lbs. 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 170 ft. lbs. or pinion bearing preload is not correct.
  2.  


WARNING
Under no circumstances should the nut be backed off to reduce 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. Torque the nuts to 15 ft. lbs.
  2.  

Chrysler 8 3 / 8 " and 9 1 / 4 " Axles

See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Installing the pinion seal on the 8 3/8 or 9 1/4 inch drive axle



Click image to see an enlarged view

Fig. Fig. 2: Installing the pinion flange on a 8 3/8 or 9 1/4 inch drive axle



Click image to see an enlarged view

Fig. Fig. 3: Tightening the pinion nut on a 8 3/8 or 9 1/4 inch drive axle

An inch-pound torque wrench and a torque wrench capable of at least 250 ft. lbs. 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 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 relation.
  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 ip 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. 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 in. lbs. 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. or pinion bearing preload is not correct.
  2.  


WARNING
Under no circumstances should the nut be backed off to reduce 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. Torque the nuts to 15 ft. lbs.
  2.  

Chrysler 9 5 / 8 " Axle

An inch-pound torque wrench and a torque wrench capable of at least 350 ft. lbs. 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 axle.
  4.  
  5. Mark the companion flanges and U-joints for correct reinstallation position.
  6.  
  7. Remove the driveshaft.
  8.  
  9. Use a suitable tool to hold the companion flange. Remove the pinion nut and washer.
  10.  
  11. Place a drain pan under the differential, clean the area around the seal, and mark the yoke-to-pinion relation.
  12.  
  13. Use a 2-jawed puller to remove the pinion.
  14.  
  15. Remove the seal with a small prybar.
  16.  
  17. Thoroughly clean the oil seal bore.
  18.  

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 325 ft. lbs. Install a new cotter pin.
  8.  


WARNING
Under no circumstances should the nut be backed off to align the cotter pin hole.

  1. Install the driveshaft using the matchmarks.
  2.  

Dana 60 and Dana 70 Axles

A torque wrench capable of at least 300 ft. lbs. 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, hold 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 install the flange onto the pinion shaft.
  16.  
  17. Install the nut on the pinion shaft and tighten it to 250-300 ft. lbs.
  18.  
  19. Connect the driveshaft.
  20.  

 
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