Dakota, 2001-2005

Pinion Seal

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Removal & Installation



8.25 Inch Axle
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Mark the universal joint, companion flange and pinion shaft for installation reference.
  6.  
  7. Remove companion flange bolts and secure the shaft in an upright position to prevent damage to the rear universal joint.
  8.  
  9. Remove the wheel and tire assemblies.
  10.  
  11. Remove brake drums to prevent any drag.
  12.  
  13. Rotate companion flange three or four times and verify flange rotates smoothly.
  14.  
  15. Measure rotating torque of the pinion with an inch pound torque wrench and record the reading for installation reference.
  16.  
  17. Install bolts into two of the threaded holes in the companion flange 180° apart.
  18.  
  19. Position Holder 6719, or equivalent, against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719, or equivalent, is held to the flange.
  20.  
  21. Remove the pinion nut and washer.
  22.  
  23. Remove companion flange with Remover C-452, or equivalent.
  24.  
  25. Remove pinion seal with a pry tool or slide hammer mounted screw.
  26.  

To install:


NOTE
The outer perimeter of the seal is pre-coated with a special sealant.

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install new pinion seal with Installer C-4076-B and Handle C-4735-1, or equivalent.
  4.  
  5. Install companion flange on the end of the shaft with the reference marks aligned.
  6.  
  7. Install bolts into two of the threaded holes in the companion flange 180° apart.
  8.  
  9. Position Holder 6719, or equivalent, against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so Holder 6719 is held to the flange.
  10.  
  11. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719, or equivalent.
  12.  
  13. Install the pinion washer and a new pinion nut. The convex side of the washer must face outward.
    NOTE
    Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result.

  14.  
  15. Hold companion flange with Holder 6719 and tighten the pinion nut to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated.
  16.  
  17. Rotate pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.).
    NOTE
    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.

  18.  
  19. If rotating torque is low use Holder 6719 to hold the companion flange and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved.
    NOTE
    The seal replacement is unacceptable if final pinion nut torque is less than 285 Nm (210 ft. lbs.).


    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.

  20.  
  21. Install propeller shaft with the installation reference marks aligned.
  22.  
  23. Tighten companion flange bolts to 108 Nm (80 ft. lbs.).
  24.  
  25. Install the brake drums.
  26.  
  27. Check the differential housing lubricant level.
  28.  
  29. Install wheel and tire assemblies and lower the vehicle.
  30.  

9.25 Inch Axle
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the wheel and tire assemblies.
  6.  
  7. Mark the universal joint, companion flange and pinion shaft for installation reference.
  8.  
  9. Remove the propeller shaft from the companion flange.
  10.  
  11. Remove the brake drums to prevent any drag.
  12.  
  13. Rotate the companion flange three or four times and record the pinion rotating torque with an inch pound torque wrench.
  14.  
  15. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A, or equivalent, against the companion flange and install and tighten two bolts and washers into the remaining holes.
  16.  
  17. Hold the companion flange with Holder 6719A, or equivalent, and remove pinion nut and washer.
  18.  
  19. Remove the companion flange with Remover C-452, or equivalent.
  20.  
  21. Remove the pinion seal with pry tool or slide hammer mounted screw.
  22.  

To install:

  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2.  
  3. Install a new pinion seal with Installer C-3860-A and Handle C-4171, or equivalent.
  4.  
  5. Install the companion flange on the end of the shaft with the reference marks aligned.
  6.  
  7. Install two bolts into the threaded holes in the companion flange, 180° apart.
  8.  
  9. Position Holder 6719, or equivalent, against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange.
  10.  
  11. Install the companion flange on the pinion shaft with Installer C-3718 and Holder 6719, or equivalent.
  12.  
  13. Install the pinion washer and a new pinion nut. The convex side of the washer must face outward.
    NOTE
    Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Damage to the collapsible spacer or bearings may result.

  14.  
  15. Hold the companion flange with Holder 6719 and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate the pinion several revolutions to ensure the bearing rollers are seated.
  16.  
  17. Rotate the pinion with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.).
    NOTE
    Never loosen the pinion nut to decrease pinion bearing rotating torque and never exceed the specified preload torque. If the rotating torque is exceeded, a new collapsible spacer must be installed.

  18.  
  19. If the rotating torque is low, use Holder 6719 to hold the companion flange and tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until the proper rotating torque is achieved.
    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.


    NOTE
    The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.).

  20.  
  21. Install the propeller shaft with the installation reference marks aligned.
  22.  
  23. Tighten the companion flange bolts to 108 Nm (80 ft. lbs.).
  24.  
  25. Install the brake drums, wheel and tire assemblies and lower the vehicle.
  26.  
  27. Check the differential lubricant level.
  28.  

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 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.  

 
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