Ram B1500, B2500, B3500, 1999-2003

Pinion Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  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.
  12.  

216 Fbi, 248fbi Axles
  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Scribe marks on the universal joints, pinion yokes, and pinion shafts 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 calipers and rotor 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.  
  5. Position the pinion yoke on the end of the shaft with the reference marks aligned.
  6.  
  7. Seat the yoke on the pinion shaft.
  8.  
  9. Install the pinion yoke washer. The convex side of the washer must face outward.
  10.  


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. Rotate the pinion shaft several revolutions to ensure the bearing rollers are seated.
  2.  
  3. 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.
  4.  
  5. The remainder of the procedure is the reverse of removal.
  6.  
  7. Lower the vehicle.
  8.  

C-Clip Type
  1. Before servicing the vehicle, refer to the Precautions Section.
  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.  

C205f, 194 Fia Axles


Click image to see an enlarged view

Fig. Checking pinion rotation torque-C205F axle



Click image to see an enlarged view

Fig. Removing the pinion flange nut-typical



Click image to see an enlarged view

Fig. Tightening the pinion nut-C205F axle


NOTE
C250F axles are equipped with a flange on the input shaft; 194 FIA axles have a yoke. The procedures apply to both, but with this difference.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the skidplate, if fitted.
  4.  
  5. Scribe marks on the universal joints, pinion yokes, flanges and pinion shafts for installation reference.
  6.  
  7. Disconnect the front driveshaft from the axle.
  8.  
  9. Secure the driveshaft in an upright position to prevent damage to the rear universal joint.
  10.  
  11. Remove the halfshafts.
  12.  
  13. Rotate the pinion flange 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. Devise a method of holding the flange or yoke from turning. If the special tool is not available, the bolt holes and bolts can be utilized.
  18.  
  19. Hold the flange or yoke in position with a pipe wrench or other suitable tool. Remove the pinion shaft nut. A new nut should be used on assembly.
  20.  
  21. Remove the flange or yoke. A puller will probably be needed.
  22.  
  23. 194 FIA axle: remove the pinion seal excluder from the yoke.
  24.  
  25. Remove the pinion shaft seal with suitable prytool or slide-hammer mounted screw.
  26.  

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 flange or yoke for cracks, worn splines and worn seal contact surface. Replace flange or 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.  
  5. 194 FIA axle: install a new pinion seal excluder to the pinion yoke.
  6.  
  7. Install the flange or yoke and nut and washer. A new nut should be used. Tighten the nut until there zero bearing end-play.
  8.  


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

  1. Hold the pinion flange with a suitable tool and tighten shaft nut to 200 ft. lbs. (271 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. The torque sequence will then have to be repeated.

  1. The remainder of the procedure is the reverse of removal.
  2.  
  3. Lower the vehicle.
  4.  

Non C-Clip Type
  1. Before servicing the vehicle, refer to the Precautions Section.
  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.
  12.  

 
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