Ram Truck 1500, 2500 & 3500 (2006-2008)

Pinion Seal

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Removal & Installation



275FBI
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With the vehicle in neutral, position vehicle on hoist.
  4.  
  5. Remove the propeller shaft.
  6.  
  7. Bend the pinion flange nut collar lock out of the pinion shaft keyway.
  8.  
  9. Hold the pinion flange with Holder C-3281 and remove pinion flange nut.
  10.  
  11. Mark a line across the pinion shaft and flange for installation reference.

    Click image to see an enlarged view

    Fig. Pinion flange (1) with Holder C -3281 (2)

  12.  
  13. Remove pinion flange with pinion flange puller 8992.

    Click image to see an enlarged view

    Fig. Pinion flange (1) pinion flange puller 8992 (2)

  14.  
  15. Remove pinion seal with a seal puller.
  16.  

To install:

  1. Install new pinion seal with installer 10069.
  2.  
  3. Apply a light coat of teflon thread sealant, to pinion flange splines.
  4.  
  5. Position flange on pinion shaft with reference marks aligned.
  6.  
  7. Install pinion flange and new pinion nut.
  8.  
  9. Hold flange with Holder C-3281 and tighten pinion nut to 369 ft. lbs. (500 Nm)
  10.  
  11. Bend pinion flange nut collar into pinion keyway with a hammer and punch.
  12.  
  13. Install propeller shaft with reference marks aligned.
  14.  
  15. Check the fluid level and add as needed.
  16.  

9.25 in. AA
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Mark propeller shaft and pinion flange for installation reference.
  4.  
  5. Remove the propeller shaft.
  6.  
  7. Remove the hub bearings and axle shafts.
  8.  
  9. Rotate pinion gear three or four times.
  10.  
  11. Record pinion torque to rotate with an inch pound torque wrench for installation reference.
  12.  
  13. Hold pinion flange with flange wrench 8979 and remove pinion flange nut and washer.
  14.  
  15. Mark a line across the pinion shaft and flange for installation reference.
  16.  
  17. Remove pinion flange with pinion flange puller 8992.
  18.  
  19. Remove pinion seal with a seal puller.

    Click image to see an enlarged view

    Fig. Pinion flange removal with tool 8992

  20.  

To install:

  1. Install new pinion seal with Installer 8882 and Handle C-4171.
  2.  
  3. Install flange on the pinion shaft with the reference marks aligned.
  4.  
  5. Lightly tap pinion flange onto the pinion, until a few threads are showing.
  6.  
  7. Install flange washer and new pinion nut.
  8.  
  9. Hold flange with flange wrench 8979 and tighten pinion nut until pinion end play is taken up.
  10.  
  11. Rotate pinion flange several times to seat bearings.
  12.  
  13. Measure pinion torque to rotate with an inch pound torque wrench. Pinion torque to rotate should be equal to recorded reading plus an additional 3-5 inch. lbs. (0.40-0.57 Nm).
  14.  
  15. If torque to rotating is low, tighten the pinion nut in 5 ft. lbs. (6.8 Nm) increments until pinion torque to rotate is achieved.
  16.  
  17. Rotate pinion several times then verify pinion torque to rotate again.
  18.  
  19. Install the axle shafts and hub bearings.
  20.  
  21. Install propeller shaft with reference marks aligned.
  22.  

C205FD
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. With axle in 2WD remove front propeller shaft and left half shaft.
  4.  
  5. Rotate pinion gear three or four times and verify pinion rotates smoothly.
  6.  
  7. Record pinion torque to rotate with an inch pound torque wrench, for installation reference.
  8.  
  9. Position Holder 6719 against the companion flange and install a four bolts and washers into the threaded holes and tighten the bolts.
  10.  
  11. Remove pinion nut.
  12.  
  13. Mark a line across the pinion shaft and flange for installation reference.
  14.  
  15. Remove the companion flange with Remover C-452.
  16.  
  17. Remove pinion seal with a seal puller.

    Click image to see an enlarged view

    Fig. Pinion flange (1) removal with C-452 (2)

  18.  

To install:

  1. Apply a light coating of gear lubricant on the lip of pinion seal
  2.  
  3. Install seal with Installer 8695 and Handle C-4171.
  4.  
  5. Install flange on the pinion shaft with the reference marks aligned.
  6.  
  7. Install companion flange onto the pinion with Installer C-3718 and Holder 6719A.
  8.  
  9. 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.
  10.  
  11. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play
    WARNING
    Do not exceed 200 ft. lbs. (271 Nm) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions will damage the axle.

  12.  
  13. Measure pinion Torque To Rotate with an inch pound torque wrench. Pinion Torque To Rotate should be equal to recorded reading plus an additional 5 inch. lbs. (0.56 Nm).
  14.  
  15. If rotating torque is low, tighten the pinion nut in 5 ft. lbs. (6.8 Nm) increments until pinion Torque To Rotate is achieved.
    WARNING
    If maximum tightening torque 350 ft. lbs. (475 Nm) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instructions will damage the axle.

  16.  
  17. Install the propeller shaft and the left half shaft.
  18.  
  19. Check the fluid level and add as needed.
  20.  

 
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