Dodge Durango

 Service Manual

Differential and Driveline » 8 1/4 And 9 1/4 axle » Removal and installation
Pinion gear

NOTE: The ring gear and pinion are serviced in a matched set. Do not replace the pinion without replacing the ring gear.

REMOVAL

(1) Remove differential from the axle housing.

(2) Mark the companion flange and propeller shaft for installation alignment.

(3) Disconnect the propeller shaft from the companion flange. Using suitable wire, tie propeller shaft to underbody.

(4) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(5) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

(6) Use Holder 6719 to hold companion flange and remove the companion flange nut and washer.

(7) Using Remover C-452, remove the companion flange from the pinion (Fig. 27).

Fig. 27 Companion Flange Removal

1 - COMPANION FLANGE

2 - PULLER TOOL

(8) Partially install pinion nut onto pinion to protect the threads.

(9) Remove the pinion from housing (Fig. 28).

Catch the pinion with your hand to prevent it from falling and being damaged.

(10) Remove the pinion shaft seal with suitable pry tool or slide-hammer mounted screw.

(11) Remove oil slinger, if equipped, and front pinion bearing.

Fig. 28 Remove Pinion

1 - RAWHIDE HAMMER

(12) Remove the front pinion bearing cup with:

• Remover C-4345 and Handle C-4171 for the 8 1/4 axles (Fig. 29).
• Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 for the 9 1/4 axles.

Fig. 29 Front Bearing Cup Removal

1 - REMOVER

2 - HANDLE

(13) Remove the rear bearing cup from housing (Fig. 30). Use:

• Remover C-4307 and Handle C-4171 for the 8 1/4 axle.
• Remover C-4309 and Handle C-4171 for the 9 1/4 axle.

Fig. 30 Rear Bearing Cup Removal

1 - DRIVER

2 - HANDLE

(14) Remove the collapsible preload spacer (Fig.

31).

(15) Remove the rear bearing from the pinion (Fig.

32) with:

• Puller/Press C-293-PA and Adapters C-293-47 for the 8 1/4 axle.
• Puller/Press C-293-PA and Adapters C-293-37 for the 9 1/4 axle.

Place 4 adapter blocks so they do not damage the bearing cage.

(16) Remove the depth shims from the pinion shaft. Record the thickness of the depth shims.

INSTALLATION

(1) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(2) Install the pinion rear bearing cup (Fig. 33) with:

• Installer C-4308 and Driver Handle C-4171 for the 8 1/4 axle.
• Installer C-4310 and Driver Handle C-4171 for the 9 1/4 axle.

(2) Ensure cup is correctly seated.

(3) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

Fig. 31 Collapsible Spacer

1 - COLLAPSIBLE SPACER

2 - SHOULDER

3 - PINION GEAR

4 - OIL SLINGER

5 - REAR BEARING

Fig. 32 Rear Bearing Removal

1 - SPECIAL TOOL C-293-PA

2 - VISE

3 - ADAPTERS

4 - DRIVE PINION GEAR SHAFT

Fig. 33 Pinion Rear Bearing Cup Installation

1 - INSTALLER

2 - HANDLE

(4) Install the pinion front bearing cup (Fig. 34) with:

• Installer D-130 and Handle C-4171 for the 8 1/4 axle.
• Installer D-129 and Handle C-4171 for the 9 1/4 axle.

Fig. 34 Pinion Front Bearing Cup Installation

1 - INSTALLER

2 - HANDLE

(5) Install pinion front bearing, and oil slinger, if equipped.

(6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with:

• Installer C-4076-B and Handle C-4735-1 for the 8 1/4 axle (Fig. 35).
• Installer C-3860-A and Handle C-4171 for the 9 1/4 axle.

Fig. 35 Pinion Seal Installation-8 1/4 Axle

1 - SPECIAL TOOL C-4735

2 - DIFFERENTIAL HOUSING

3 - SPECIAL TOOL C-4076-A

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion head to achieve proper ring gear and pinion mesh. If the factory installed ring gear and pinion are reused, the pinion depth shim should not require replacement.

If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing.

(7) Place the proper thickness depth shim on the pinion shaft.

(8) Install the rear bearing and slinger, if equipped, on the pinion (Fig. 36) with:

• Installer 6448 for the 8 1/4 axle
• Installer C-3095 for the 9 1/4 axle.

(9) Install a new collapsible preload spacer on pinion shaft and install the pinion in the housing (Fig.

37).

(10) Install the pinion in housing.

(11) Install the companion flange with Installer C-3718 and Holder 6719.

(12) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(13) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

Fig. 36 Shaft Rear Bearing Installation

1 - PRESS

2 - INSTALLATION TOOL

3 - DRIVE PINION GEAR

4 - DRIVE PINION GEAR SHAFT REAR BEARING

Fig. 37 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER

2 - SHOULDER

3 - PINION GEAR

4 - OIL SLINGER

5 - REAR BEARING

(14) Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing endplay if a new collapsible spacer was installed.

(15) Tighten the nut to 285 N*m (210 ft. lbs.) (Fig.

38).

CAUTION: 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. The torque sequence will then have to be repeated.

Fig. 38 Tighten the Pinion Nut

1 - DIFFERENTIAL HOUSING

2 - COMPANION FLANGE HOLDER

3 - TORQUE WRENCH

(16) Using Holder 6719, crush collapsible spacer until bearing end play is taken up.

(17) Slowly tighten the nut in 6.8 N*m (5 ft. lbs.) increments until the desired rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer (Fig. 39).

(18) Check bearing rotating torque with an inch pound torque wrench (Fig. 39). The torque necessary to rotate the pinion should be:

• Original Bearings - 1 to 3 N*m (10 to 20 in.

  lbs.).

• New Bearings - 2 to 5 N*m (15 to 35 in. lbs.).

  (19) Install propeller shaft.

  (20) Install differential in housing.

Fig. 39 Check pinion Rotating Torque

1 - COMPANION FLANGE

2 - INCH POUND TORQUE WRENCH

Rear axle

Axle shaft

8 1/4 And 9 1/4 axle seal and bearing

Pinion seal

Differential

Differential side bearings

Ring gear and exciter ring

Pinion gear

Final assembly