Durango, 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. With vehicle in neutral, position vehicle on hoist.
  4.  
  5. Mark a reference line across the axle flange and propeller shaft flange.
  6.  
  7. Remove propeller shaft.
  8.  
  9. Remove brake calipers and rotors to prevent any drag.
  10.  
  11. Rotate flange three or four times and verify flange rotates smoothly.
  12.  
  13. Measure torque to rotating pinion flange with an inch pound torque wrench. Record reading for installation reference.
  14.  
  15. Install bolts into two of the threaded holes in the flange 180° apart.
  16.  
  17. Position Holder 6719 against the flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
  18.  
  19. Remove pinion nut and washer.
  20.  
  21. Remove flange with Remover C-452.
  22.  
  23. Remove pinion seal with a pry tool or slide-hammer mounted screw.
  24.  

To install:

  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.
  4.  
  5. Install flange on the end of the shaft with the reference marks aligned.
  6.  
  7. Install bolts into two of the threaded holes in the flange 180° apart.
  8.  
  9. Position Holder 6719 against flange. Install a bolt and washer into one of the remaining threaded holes. Tighten bolts so Holder 6719 is held to the flange.
  10.  
  11. Install flange on pinion shaft with Installer C-3718 and Holder 6719.
  12.  
  13. Install pinion washer and a new pinion nut. The convex side of the washer must face outward.
    CAUTION
    Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Failure to follow these instructions can damage the collapsible spacer or bearings.

  14.  
  15. Hold flange with Holder 6719 and tighten pinion nut to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure bearing rollers are seated.
  16.  
  17. Rotate pinion flange 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.).
    CAUTION
    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. Failure to follow these instructions can damage the collapsible spacer or bearings.

  18.  
  19. If rotating torque is low use Holder 6719, to hold 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.
  22.  
  23. Install rear brake rotors components.
  24.  

9.25 Inch Axle
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. With vehicle in neutral, position it on a hoist.
  4.  
  5. Mark an installation reference line across the pinion flange and driveshaft flange.
  6.  
  7. Remove driveshaft.
  8.  
  9. Remove brake calipers and rotors to prevent any drag.
  10.  
  11. Rotate pinion flange three or four times and verify flange rotates smoothly.
  12.  
  13. Measure rotating torque of the pinion with an inch pound torque wrench and record reading.
  14.  
  15. Install two bolts into the pinion flange threaded holes, 180° apart. Position Holder 6719A, or equivalent, against the flange and install and tighten two bolts and washers into the remaining holes.
  16.  
  17. Hold the flange with Holder 6719A, or equivalent, and remove pinion nut and washer.
  18.  
  19. Remove companion flange with Remover C-452, or equivalent.
  20.  
  21. Remove 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 new pinion seal with Installer C-4076-B and Handle C-4735, or equivalent.
  4.  
  5. Install pinion flange on pinion shaft with Installer C-3718, or equivalent.
  6.  
  7. Install two bolts into the threaded holes in the flange, 180° apart.
  8.  
  9. Position Holder 6719 against the 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 pinion washer and a new pinion nut. The convex side of the washer must face outward.
    CAUTION
    Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instructions will result in damage to collapsible spacer or bearings.

  12.  
  13. Hold companion flange with Holder 6719, or equivalent, and tighten pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated.
  14.  
  15. 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.).
    CAUTION
    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. Failure to follow these instructions will result in damage to the collapsible spacer

  16.  
  17. If rotating torque is low, use Holder 6719, or equivalent, 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 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.).

  18.  
  19. Install driveshaft.
  20.  

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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