Assembly

ASSEMBLY

Special Tools:














1. Install the pinion head bearing using Installer (3) and Handle (2).





2. Install the outer pinion bearing cup using Installer and Handle.





3. Install bearing (4) on pinion (3) using Installer (2) and press (1).





4. Install a new collapsible spacer (2) onto the pinion shaft (1).





5. Install the pinion into the housing and place the outer bearing over the pinion.





6. Install the pinion nut (1) onto the pinion shaft (3).





7. Using Spline Holder (1) and Socket (2), tighten pinion nut to 74 Nm (54 ft. lbs.).





8. Install the pinion seal using Installer (2) and a hammer (1).





9. Install side gears (2), shims (4) and pinion gears (3) into carrier (1).
10. Install the pinion gear shaft into the pinion gears and start the roll pin.





11. Use a pin punch to install the roll pin (1).





12. Apply MOPAR(R) Lock AND Seal Adhesive or an equivalent to the ring gear bolts (1).
13. Install ring gear (2) onto the carrier.
14. Install ring gear bolts (1) and tighten to 41 Nm (30 ft. lbs.).





15. Press ring gear side (3) carrier bearing (2) onto shaft using Installer (1) and press (4).





16. Coat the ring and pinion gears with pattern grease before assembling.
17. Press pinion gear side (3) carrier bearing (2) onto shaft using Installer (1) and press (4).





18. Install measured side shims (3) and carrier (1) into the carrier housing (2).
19. Apply a bead of MOPAR(R) AXLE RTV on the case to seal the cover.





20. Install cover onto carrier case.
21. Tighten cap bolts (2) to 48 Nm (35 ft. lbs.) and tighten cover bolts (1) to 23 Nm (16 ft. lbs.).
22. Open the window on the cover and do a pattern check of the gears.





23. Place pinion side axle seal (1) onto Installer (3) with lip side down (2).





24. Install pinion side axle seal using Installer (2) and Handle (1).





25. Place pinion side axle seal (1) onto Installer (3) with lip side down (2).





26. Install ring gear side axle seal using Installer (2) and Handle (1).





27. Remove all old gasket material on the mating surfaces of the ECC and RDA. Coat the edge face with liquid gasket. Install wave washer.
28. Install the ECC to the RDA and tighten the bolts to 78 Nm (58 ft. lbs.).