Dakota, 2001-2005

Pinion Seal

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Removal & Installation



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove skid plate, if equipped.
  6.  
  7. Remove both half shafts.
  8.  
  9. Mark the propeller shaft and pinion companion flange for installation reference.
  10.  
  11. Remove the front propeller shaft.
  12.  
  13. Rotate the pinion gear three or four times and verify pinion rotates smoothly.
  14.  
  15. Record pinion rotating torque with an inch pound torque wrench, for installation reference.
  16.  
  17. Position Holder 6719, or equivalent, against the companion flange and install a four bolts and washers into the threaded holes and tighten the bolts.
  18.  
  19. Remove the pinion nut.
  20.  
  21. Remove the companion flange with Remover C-452, or equivalent.
  22.  
  23. Remove pinion seal with a pry tool or a slide hammer mounted screw.
  24.  

To install:

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install seal with Installer C-3972-A and Handle C-4171, or equivalent,
  4.  
  5. Install the companion flange onto the pinion with Installer C-3718 and Holder 6719A, or equivalent.
  6.  
  7. Position holder against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange.
  8.  
  9. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play.
    NOTE
    Do not exceed the minimum tightening torque when installing the companion flange at this point. Damage to the collapsible spacer or bearings may result.

  10.  
  11. Tighten the nut to 200 ft. lbs. (271 Nm).
    NOTE
    Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.

  12.  
  13. Record the pinion rotating torque using a torque wrench. The rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.).
  14.  
  15. If the rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved.
    NOTE
    If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

  16.  
  17. Install propeller shaft with reference marks aligned.
  18.  
  19. Add gear lubricant to differential housing if necessary.
  20.  
  21. Install half shafts.
  22.  

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 210 ft. lbs. (285 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.
  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
     
    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, replace the collapsible spacer.
  8.  
  9. Install or connect the following:

    Driveshaft
     
    Brake rotors
     
    Wheels
     

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

    Click image to see an enlarged view

    Fig. Removing the companion flange



    Click image to see an enlarged view

    Fig. Measuring pinion rotating torque



    Click image to see an enlarged view

    Fig. Pinion seal installer



    Click image to see an enlarged view

    Fig. Tightening the pinion nut

  12.  

 
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