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-
bling them.
(3) Align the inner race, cage and housing accord-
ing to the alignment reference marks.
(4) Insert the inner race into the cage (Fig. 10) and
rotate race into the cage.
(5) Rotate the inner race/hub in the cage (Fig. 11).
HALF SHAFT
3 - 14
CV JOINT-OUTER (Continued)DR
Fig.7BEARING
Fig.9INNERRACE/HUB
1 - HOUSING 2 - INNER RACE/HUB 3 - BEARING CAGE 4 - BALL
Fig.10INNERRACE/HUB
1 - INNER RACE/HUB 2 - BEARING CAGE
Fig.8CAGEANDINNERRACE/HUB
1 - HOUSING 2 - INNER RACE 3 - CAGE WINDOW
(6) Insert cage into the housing (Fig. 12). Rotate the cage 90° into the housing so the large bearing hub counterbore is facing outwards.
(7) Apply the grease supplied with the joint/boot to the ball races. Spread the grease equally between all the races.
(8) Tilt inner race/hub and cage and install the
balls (Fig. 13).
(9) Place new clamps onto new boot and slide boot
onto the shaft to it’s original position.
(10) Apply the rest of grease to the C/V joint and
boot.
Fig.11CAGEANDINNERRACE/HUB
1 - CAGE WINDOWS 2 - SNAP RING
DR CV JOINT-OUTER (Continued)
HALF SHAFT
3 - 15
Fig.12BEARINGCAGEANDHOUSING
Fig.14OUTERC/VJOINT
1 - OUTER RACE 2 - BEARING CAGE WINDOW 3 - CV JOINT HOUSING
1 - SNAP RING 2 - SHAFT TAPER 3 - SNAP RING GROVE 4 - BEARING HUB
NOTE: Verify boot is not twisted and remove any excess air.
(13) Secure both boot clamps (Fig. 15) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until jaws of the tool are closed.
Fig.13BALLBEARING
1 - C/V HOUSING 2 - INNER RACE/HUB 3 - BEARING CAGE 4 - BEARING
(11) Install the joint onto the shaft. Push the joint onto the shaft until the snap ring seats in the groove (Fig. 14).
NOTE: Pull on the joint to verify the span ring has engaged.
(12) Position the boot on the joint in it’s original
position.
Fig.15BOOTCLAMPLOCATIONS
1 - C/V HOUSING 2 - CLAMP 3 - HALF SHAFT 4 - CLAMP 5 - C/V BOOT
3 - 16
HALF SHAFT
CV JOINT-INNER REMOVAL
DR
(1) Clamp shaft in a vise (with soft jaws) and sup-
(2) Remove clamps with a cut-off wheel or grinder
port C/V joint.
(Fig. 16).
CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder.
Fig.18TRIPODSNAPRING
1 - SNAP RING 2 - TRIPOD 3 - PLIERS
(6) Remove tripod and boot from the half shaft. (7) Clean and inspect C/V components for exces- sive wear and damage. Replace the tripod as a unit only if necessary.
INSTALLATION
(1) Clean all C/V joint components and shaft. (2) Slide new boot down the half shaft. (3) Install tripod and tripod snap ring on the half
shaft (Fig. 19).
Fig.16BOOTCLAMPLOCATION
1 - C/V HOUSING 2 - CLAMP 3 - BOOT 4 - CLAMP
(3) Remove housing from the half shaft (Fig. 17)
and slide boot down shaft.
Fig.19C/VTRIPOD
1 - BOOT 2 - TRIPOD
Fig.17C/VHOUSING
1 - BOOT 2 - HOUSING
(4) Remove housing bushing from the housing. (5) Remove tripod snap ring (Fig. 18).
(4) Pack grease supplied with the joint/boot into
the housing and boot.
(5) Coat tripod with supplied grease. (6) Install new bushing (Fig. 20) onto the housing. (7) Insert the tripod and shaft in the housing.
DR CV JOINT-INNER (Continued)
HALF SHAFT
3 - 17
Fig.20HOUSINGBUSHING
1 - BUSHING 2 - HOUSING
(8) Position the boot on the joint and shaft in it’s
original position (Fig. 21).
NOTE: Verify boot is not twisted and remove any excess air.
(9) Measure the distance from the end of the hous- ing to the end of the boot on the shaft. This measure- ment should be 260 mm (10.25 in.).
Fig.21INNERC/VBOOT
1 - CLAMP 2 - BOOT 3 - CLAMP 4 - SHAFT 5 - HOUSING
NOTE: If measurement is not correct, allow more or less air into the boot.
(10) Secure both boot clamps with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed.
3 - 18
FRONT AXLE - C205F
FRONT AXLE - C205F
TABLE OF CONTENTS
page
DR
page
FRONT AXLE - C205F
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 30AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT AXLE - C205F DESCRIPTION
The axle consists of an alumunum center section with an axle tube extending from one side. The tube is pressed into the differential housing. The power is transferred from the axle through two constant veloc- ity (C/V) drive shafts to the wheel hubs. The drive shafts are identical and interchangeable.
OPERATION
The axle receives power from the propeller shaft. The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case. The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are splined to the axle shafts.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri- cant, incorrect backlash, tooth contact, worn/damaged gears or the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are accelera- tion, deceleration, coast, or constant load.
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35DIFFERENTIAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then acceler- ate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the noise stops or changes greatly:
† Check for insufficient lubricant. † Incorrect ring gear backlash. † Gear damage. Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during vehi- cle turns. A worn pinion mate shaft can also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound. Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differen- tial. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front pinion bearing is the source.
Worn or damaged differential bearings usually pro- duce a low pitch noise. Differential bearing noise is similar to pinion bearing noise. The pitch of differen-
DR FRONT AXLE - C205F (Continued)
tial bearing noise is also constant and varies only with vehicle speed.
Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn U-joint or by worn side-gear thrust washers. A worn pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually caused by: † Damaged drive shaft. † Missing drive shaft balance weight(s). † Worn or out of balance wheels. † Loose wheel lug nuts. † Worn U-joint(s). † Loose/broken springs. † Damaged axle shaft bearing(s). † Loose pinion gear nut. † Excessive pinion yoke run out. † Bent axle shaft(s).
FRONT AXLE - C205F
3 - 19
Check for loose or damaged front end components or engine/transmission mounts. These components can contribute to what appears to be a rear end vibration. Do not overlook engine accessories, brack- ets and drive belts.
All driveline components
should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
into gear (or the clutch engaged) can be caused by:
A snap or clunk noise when the vehicle is shifted † High engine idle speed. † Transmission shift operation. † Loose engine/transmission/transfer case mounts. † Worn U-joints. † Loose spring mounts. † Loose pinion gear nut and yoke. † Excessive ring gear backlash. † Excessive side gear to case clearance. The source of a snap or a clunk noise can be deter- mined with the assistance of a helper. Raise the vehi- cle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.
DIAGNOSTIC CHART
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
2. Bent or sprung axle shaft. 3. End-play in pinion bearings.
4. Excessive gear backlash between the ring gear and pinion.
5. Improper adjustment of pinion gear bearings. 6. Loose pinion yoke nut. 7. Scuffed gear tooth contact surfaces.
1. Inspect axle tube alignment. Correct as necessary.
2. Inspect and correct as necessary. 3. Refer to pinion pre-load information and correct as necessary. 4. Check adjustment of the ring gear and pinion backlash. Correct as necessary. 5. Adjust the pinion bearings pre-load. 6. Tighten the pinion yoke nut. 7. Inspect and replace as necessary.
FRONT AXLE - C205F
3 - 20
FRONT AXLE - C205F (Continued)DR
Condition
Possible Causes
Correction
Axle Shaft Broke
1. Misaligned axle tube.
2 Vehicle overloaded.
3. Erratic clutch operation.
4. Grabbing clutch.
Differential Cracked
1. Improper adjustment of the differential bearings.
2. Excessive ring gear backlash.
3. Vehicle overloaded.
4. Erratic clutch operation.
Differential Gears Scored
1. Insufficient lubrication.
2. Improper grade of lubricant.
3. Excessive spinning of one wheel/tire.
Loss Of Lubricant
1. Lubricant level too high.
2. Worn axle shaft seals. 3. Cracked differential housing. 4. Worn pinion seal. 5. Worn/scored yoke. 6. Axle cover not properly sealed.
1. Replace the broken shaft after correcting tube mis-alignment.
2. Replace broken shaft and avoid excessive weight on vehicle. 3. Replace broken shaft and avoid or correct erratic clutch operation. 4. Replace broken shaft and inspect and repair clutch as necessary.
1. Replace case and inspect gears and bearings for further damage. Set differential bearing pre-load properly.
2. Replace case and inspect gears and bearings for further damage. Set ring gear backlash properly. 3. Replace case and inspect gears and bearings for further damage. Avoid excessive vehicle weight. 4. Replace case and inspect gears and bearings for further damage. Avoid erratic use of clutch.
1. Replace scored gears. Fill differential with the correct fluid type and quantity.
2. Replace scored gears. Fill differential with the correct fluid type and quantity. 3. Replace scored gears. Inspect all gears, pinion bores, and shaft for damage. Service as necessary.
1. Drain lubricant to the correct level.
2. Replace seals. 3. Repair as necessary. 4. Replace seal. 5. Replace yoke and seal. 6. Remove, clean, and re-seal cover.
Axle Overheating
1. Lubricant level low.
1. Fill differential to correct level.
2. Improper grade of lubricant.
3. Bearing pre-loads too high. 4. Insufficient ring gear backlash.
2. Fill differential with the correct fluid type and quantity. 3. Re-adjust bearing pre-loads. 4. Re-adjust ring gear backlash.
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 21
Condition
Possible Causes
Correction
Gear Teeth Broke
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
Axle Noise
1. Insufficient lubricant.
2. Improper ring gear and pinion adjustment. 3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or pinion. 5. Loose pinion bearings. 6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap bolts.
9. Housing not machined properly.
REMOVAL
INSTALLATION
1. Replace gears. Examine other gears and bearings for possible damage.
2. Replace gears and examine the remaining parts for damage. Avoid erratic clutch operation. 3. Replace gears and examine remaining parts for damage. 4. Replace gears and examine remaining parts for damage. Ensure ring gear backlash is correct.
1. Fill differential with the correct fluid type and quantity. 2. Check ring gear and pinion contact pattern. 3. Replace gears with a matched ring gear and pinion. 4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load. 6. Adjust differential bearing pre-load. 7. Measure ring gear run-out. Replace components as necessary. 8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification. 9. Replace housing.
(1) Place transmission in netural. (2) Raise and support the vehicle. (3) Remove tire and wheel assemblies. (4) Remove axle half shafts. (5) Remove exhaust crossover. (6) Mark front propeller shaft and remove shaft. (7) Remove
suspension crossmember mounting
bolts (Fig. 1) and remove crossmember. (8) Support axle with hydraulic jack. (9) Remove axle housing pinion mounting bolts
(1) Raise axle into position. (2) Install axle mounting bolts and tighten nuts to
95 N·m (70 ft. lbs.).
(3) Install
suspension crossmember and bolts.
Tighten crossmember nuts to 102 N·m (75 ft. lbs.).
(4) Install
front propeller shaft with reference marks aligned (Fig. 5) and tighten bolts to 115 N·m (85 ft. lbs.).
(5) Install exhaust crossover. (6) Install axle half shafts. (7) Check the differential fluid level and add fluid
(10) Remove axle shaft tube mounting bolts (Fig.
if necessary.
(11) Remove differential housing mounting bolts
(8) Install tire and wheel assemblies. (9) Remove support lower the vehicle.
(Fig. 2).
3).
(Fig. 4).
(12) Lower axle from the vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets only. The identifying numbers for the ring gear and
FRONT AXLE - C205F
3 - 22
FRONT AXLE - C205F (Continued)DR
Fig.1SUSPENSIONCROSSMEMBER
1 - PINION FLANGE 2 - AXLE TUBE MOUNTING BRACKET 3 - CROSSMEMBER BOLTS
Fig.3AXLETUBEMOUNT
1 - MOUNTING BOLTS 2 - BOLTS
Fig.2HOUSINGPINIONMOUNTINGBOLTS
1 - MOUNTING BOLTS 2 - PINION FLANGE
pinion are painted onto the pinion gear shaft and the side of the ring gear. A plus (+) number, minus (–) number or zero (0) along with the gear set sequence number (01 to 99) is on each gear. This first number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion marked with a (0). The next two numbers are the sequence number of the gear set. The standard set- ting from the center line of the ring gear to the back
Fig.4DIFFERENTIALMOUNT
1 - DIFFERENTIAL MOUNT 2 - DIFFERENTIAL HOUSING 3 - MOUNTING BOLTS
face of the pinion is 99.690 mm (3.925 in.). The stan- dard depth provides the best teeth contact pattern.
Compensation for
is achieved with select shims. The shims are placed
pinion depth variance
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 23
Fig.6ADJUSTMENTSHIM
1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER
Depth Variance charts. Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus amount needed.
Note the painted number on the shaft of the drive pinion (–1, –2, 0, +1, +2, etc.). The numbers repre- sent thousands of an inch deviation from the stan- dard. If the number is negative, add that value to the required thickness of the depth shim(s). If the num- ber is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary.
Fig.5COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PROPELLER SHAFT 3 - FLANGE YOKE 4 - REFERENCE MARK
between the rear pinion bearing cone and the pinion gear head. (Fig. 6).
If a new gear set is being installed, note the depth variance marked on both the original and replace- ment pinion. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Pinion Gear
Original Pinion
Gear Depth
Variance
+4
+3
+2
+1
21
22
23
2424
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001PINION GEAR DEPTH VARIANCE
New Pinion Gear Depth Variance
23
22
21
+1
+2
+3
+0.001
+4
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001+0.003
+0.002
+0.001+0.002
+0.001+0.005
+0.004
+0.003
+0.002
+0.001+0.004
+0.003
+0.002
+0.00120.001
20.001 20.002
20.001 20.002 20.003
20.001 20.002 20.003 20.004
20.001 20.002 20.003 20.004 20.005
20.001 20.002 20.003 20.004 20.005 20.006
20.001 20.002 20.003 20.004 20.005 20.006 20.007
20.001 20.002 20.003 20.004 20.005 20.006 20.007 20.008FRONT AXLE - C205F
3 - 24
FRONT AXLE - C205F (Continued) PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin- ion bearings installed in housing. Take measure- ments with a Pinion Gauge Set, Pinion Block 8177, Arbor Discs 8541 and Dial Indicator C-3339 (Fig. 7).DR
Fig.8PINIONHEIGHTBLOCK
1 - PINION BLOCK 2 - PINION HEIGHT BLOCK
Fig.9PINIONGAUGETOOLS
1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK
with the scooter block against the pinion height block (Fig. 10). Slide the dial probe to the crest of the arbor bar and record the highest reading.
(8) Select a shim equal to the dial indicator read- ing plus the drive pinion gear depth variance number marked on the shaft of the pinion gear using the opposite sign on the variance number. For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.
Fig.7PINIONGEARDEPTHGAUGE
1 - DIAL INDICATOR 2 - ARBOR 3 - PINION HEIGHT BLOCK 4 - CONE 5 - SCREW 6 - PINION BLOCK 7 - SCOOTER BLOCK 8 - ARBOR DISC
(1) Assemble Pinion Height Block 6739, Pinion Block 8177 and rear pinion bearing onto Screw 6741
(Fig. 7).(2) Insert assembled height gauge components, rear bearing and screw into the housing through the pinion bearing cups (Fig. 8).
(3) Install front pinion bearing and Cone 6740 onto
the screw hand tight (Fig. 7).
(4) Place Arbor Discs 8541 on Arbor D-115-3 in position in the housing side bearing cradles (Fig. 9). Install differential bearing caps on arbor discs and tighten cap bolts to specification.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position in the housing so dial probe and scooter block are flush against the surface of the pinion height block. Hold scooter block in place and zero the dial indica- tor. Tighten dial indicator face lock screw.
(7) Slide the dial indicator probe across the gap between the pinion height block and the arbor bar
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 25
Fig.11ADJUSTMENTSHIM
1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER
(2) Install ring gear if necessary, on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings 8398 on differential
case.
(4) Install differential case in the housing. (5) Insert Dummy Shims 8107 3.0 mm (0.118 in.) starting point shims between both dummy bearings and the housing (Fig. 12).
Fig.10PINIONGEARDEPTHMEASUREMENT
1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH
Differential side bearing preload and gear backlash is achieved by selective shims inserted between the bearing cup and the housing. The proper shim thick- ness can be determined using slip-fit Dummy Bear- ings 8398 in place of the differential side bearings and a Dial Indicator C-3339. Before proceeding with the differential bearing preload and gear backlash measurements, measure the pinion gear depth and prepare the pinion for installation. Establishing proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion is installed, and the gear backlash shim thickness is measured. The over- all shim thickness is the total of the dial indicator reading, starting point shim thicknesses, and the preload specification added together. The gear back- lash measurement determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion side of the differential (Fig. 11).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary.
(1) Remove side bearings from differential case.
Fig.12DUMMYSHIM
1 - DUMMY SHIM 2 - DIFFERENTIAL HOUSING 3 - DIFFERENTIAL CASE 4 - DUMMY BEARINGS
FRONT AXLE - C205F
3 - 26
FRONT AXLE - C205F (Continued)DR
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow hammer to seat the differ- ential dummy bearings to each side of the differential housing (Fig. 13) and (Fig. 14).
Fig.14SEATRINGGEARSIDE
1 - HOUSING 2 - DEAD-BLOW HAMMER 3 - RING GEAR SIDE
Fig.13SEATPINIONGEARSIDE
1 - DEAD-BLOW HAMMER 2 - HOUSING 3 - PINION GEAR SIDE
(8) Install Pilot Stud C-3288-B in cover bolt hole
below ring gear.
(9) Attach Dial Indicator C-3339 to post and posi- tion dial indicator plunger on a flat surface on a ring gear bolt head (Fig. 15).
(10) Push and hold differential to the pinion gear side of the housing (Fig. 16) and zero dial indicator. (11) Push and hold differential case to the ring gear side and record dial indicator reading (Fig. 17). (12) Add the dial indicator reading to the starting point shim thicknesses to determine the total shim thickness necessary to achieve zero differential end play.
(13) Add 0.2 mm (0.008 in) to the zero end play total. This new total represents the shims needed to preload the new differential case bearings.
(14) Rotate dial indicator out of the way on pilot
stud.
(15) Remove differential case, dummy bearings
and dummy shims from the housing.
(16) Install the pinion gear in the housing. Install the companion flange and establish the correct pinion rotating torque.
Fig.15DIFFERENTIALSIDEPLAY
1 - DIFFERENTIAL 2 - PILOT STUD 3 - DIAL INDICATOR 4 - HOUSING
(17) Install differential case and Dummy Bearings in the housing with a single dummy shim on the ring gear side of the axle and tighten retaining cap bolts.
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 27
(20) Zero dial indicator face to pointer. (21) Push and hold differential case to ring gear
side of the housing.
(22) Record dial indicator reading. (23) Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. Add the resulting measure- ment to the thickness of the single dummy shim. This is the thickness of shim required to achieve proper backlash.
(24) Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.
(25) Rotate dial indicator out of the way on pilot
stud.
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates 8142-A on the housing and spread open enough to receive differential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing. (31) Rotate the differential case several times to
seat the side bearings.
ring gear tooth (Fig. 18).
(32) Position the dial indicator plunger against a
Fig.18RINGGEARBACKLASH
1 - RING GEAR 2 - DIAL INDICATOR
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
Fig.16ZERODIALINDICATOR
1 - PINION GEAR SIDE 2 - PILOT STUD 3 - DIAL INDICATOR
Fig.17RECORDDIALINDICATOR
1 - DIAL INDICATOR 2 - HOUSING 3 - RING GEAR SIDE
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 15).
(19) Push and hold differential case toward pinion.
FRONT AXLE - C205F
3 - 28
FRONT AXLE - C205F (Continued)(34) Zero dial indicator face to pointer. (35) Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12 mm (0.005 in.) and 0.20 mm (0.008 in.). If backlash is not within specifi- cations transfer the necessary amount of shim thick- ness from one side of the differential housing to the other (Fig. 19).
(36) Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern procedure.
DR
† Gear contact pattern correct (Fig. 20). Backlash
and pinion depth is correct.
Fig.20CORRECTCONTACTPATTERN
† Ring gear too far away from pinion gear (Fig. 21). Decrease backlash by moving the ring closer to the pinion gear.
Fig.19BACKLASHSHIMADJUSTMENT
GEAR CONTACT PATTERN
Fig.21INCORRECTBACKLASH
1 - COAST SIDE TOE 2 - DRIVE SIDE HEEL
† Ring gear too close to pinion gear (Fig. 22). Increase backlash, by moving the ring away from the pinion gear.
Gear tooth contact pattern is used to verify the cor- rect running position of the ring and pinion gears. This will produce low noise and long gear life. Gears which are not positioned properly may be noisy and have shorten gear life.
(1) Wipe clean each tooth of the ring gear. (2) Apply gear marking compound to all of the ring
gear teeth.
tion.
(3) Verify bearing cap bolts are torque specifica-
(4) Apply the brakes lightly to create at 14 N·m
(10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
Fig.22INCORRECTBACKLASH
1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL
DR FRONT AXLE - C205F (Continued) † Ring gear too far away from pinion gear (Fig. 23). Decrease backlash, by moving the ring closer to the pinion gear.
FRONT AXLE - C205F
3 - 29
† Pinion gear set too low (Fig. 25). Increase pinion gear height, by increasing the pinion depth shim thickness.
Fig.23INCORRECTBACKLASH
1 - DRIVE SIDE HEEL 2 - COAST SIDE HEEL
† Ring gear too close to pinion gear (Fig. 24). Increase backlash, by moving the ring away from the pinion gear.
Fig.25LOWPINIONHEIGHT
† Pinion gear set too high (Fig. 26). Decrease pin- ion depth, by decreasing the pinion depth shim thick- ness.
Fig.24INCORRECTBACKLASH
Fig.26HIGHPINIONHEIGHT
1 - DRIVE SIDE TOE 2 - COAST SIDE TOE
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION
Axle Ratio
Differential Case Flange Runout Differential Side Gear Clearance
Ring Gear Diameter Ring Gear Backlash Ring Gear Runout
Pinion Bearing Preload - New Bearings
Pinion Bearing Preload - Original Bearings
SPECIFICATION
3.55, 3.92
0.076 mm (0.003 in.)
0-0.15 mm (0-0.006 in.)
205 mm (8.0 in.)
0.12-0.20 mm (0.005-0.008 in.)
0.12 mm (0.005 in.)
2.0-2.8 N·m (18-25 in. lbs.)
1-2 N·m (10-20 in. lbs.)
FRONT AXLE - C205F
3 - 30
FRONT AXLE - C205F (Continued)TORQUE SPECIFICATIONS
DR
Ft. Lbs.
In. Lbs.
N·m 95
34
22
61
10870
25
15
45
80271-475
200-350
PULLERC-452
HOLDER6719A
HANDLEC-4171
DESCRIPTION Mounting Nuts
Differential Fill Hole Plug Differential Cover Bolts
Bearing Cap Bolts Ring Gear Bolts
Pinion Nut
SPECIAL TOOLS
PULLERC-293-PA
ADAPTERC-293-42
ADAPTERC-293-48
PLUGC-293-3
DR FRONT AXLE - C205F (Continued)
FRONT AXLE - C205F
3 - 31
REMOVER8401
REMOVER8831
INSTALLER8693
INSTALLER8692
INSTALLER8695
INSTALLER6448
INSTALLER8694
REMOVERC-4660-A
CUP8150
FRONT AXLE - C205F
3 - 32
FRONT AXLE - C205F (Continued)DR
INSTALLER5063
DIALINDICATORC-3339
PINIONBLOCK8177
DUMMYSHIM8107
PINIONDEPTHSET6775
DUMMYBEARING8398
SPREADERW-129-B
PILOTSC-3288-B
INSTALLERC-3718
ADAPTERPLATES8142A
DR
AXLE SHAFTS REMOVAL
(1) Remove half shaft from vehicle. (2) Remove skid plate, if equipped. (3) Clean axle seal area. (4) Remove snap ring from the axle shaft. (5) Remove axle with Remove 8420A Collar 8420-3
and Slide Hammer C-3752 (Fig. 27).
FRONT AXLE - C205F
3 - 33
INSTALLATION
(1) Clean axle shaft bore clean. (2) Install a new axle shaft seal with Installer
8694 and Handle C-4171.
(3) Lubricate seal lip with gear lubricant. (4) Insert axle shaft through seal, bearing, and engage it into side gear splines. Push firmly on the axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal lip.
(5) Install axle shaft O-ring. (6) Check the differential fluid level and add fluid
if necessary.
(7) Install skid plate, if necessary. (8) Install half shaft.
AXLE BEARINGS REMOVAL
(1) Remove half shaft from vehicle. (2) Remove skid plate, if equipped. (3) Clean axle seal area. (4) Remove axle shaft O-ring. (5) Remove axle shaft. (6) Remove axle shaft seal. (7) Install axle shaft bearing Remover C-4660-A in the bearing (Fig. 28). Then tighten the nut to spread the remover in the bearing.
Fig.27AXLESHAFTPULLER
1 - SNAP RING GROVE 2 - SLID HAMMER THREADS 3 - REMOVER BLOCKS 4 - REMOVER COLLAR
INSTALLATION
NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal lip.
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Insert axle shaft through seal, bearing, and engage it into side gear splines. Push firmly on the axle shaft to engage the snap-ring.
(3) Check the differential fluid level and add fluid
if necessary.
(4) Install skid plate, if necessary. (5) Install half shaft.
AXLE SHAFT SEALS REMOVAL
(1) Remove half shaft from vehicle. (2) Remove skid plate, if equipped. (3) Clean axle seal area. (4) Remove axle shaft O-ring. (5) Remove axle shaft. (6) Remove axle shaft seal with a small pry bar.
Fig.28BEARINGREMOVER
1 - AXLE BEARING 2 - NUT 3 - REMOVER
(8) Install the bearing remove cup, bearing and nut (Fig. 29). Then tighten the nut to draw the bear- ing out.
FRONT AXLE - C205F
3 - 34
AXLE BEARINGS (Continued)DR
(6) Install axle shaft O-ring. (7) Check the differential fluid level and add fluid
if necessary.
(8) Install skid plate, if necessary. (9) Install half shaft.
PINION SEAL REMOVAL
(1) Remove skid plate, if equipped. (2) Remove both half shafts. (3) Mark the propeller shaft and pinion companion
flange (Fig. 31) for installation reference.
Fig.31COMPANIONFLANGE
1 - COMPANION FLANGE 2 - PROPELLER SHAFT 3 - FLANGE YOKE 4 - REFERENCE MARK
(4) Remove the front propeller shaft. (5) Rotate the pinion gear three or four times and
verify pinion rotates smoothly.
(6) Record pinion rotating torque with an inch pound torque wrench, for installation reference (Fig. 32).
(7) Position Holder 6719 against the companion flange and install a four bolts and washers into the threaded holes and tighten the bolts.
(8) Remove the pinion nut. (9) Remove the companion flange with Remover
C-452 (Fig. 33).
(10) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
Fig.29BEARINGREMOVERCUP
1 - REMOVER CUP 2 - BEARING 3 - NUT
(9) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wipe the axle shaft tube bore clean. (2) Install axle shaft bearing with Installer 5063
and Handle C-4171 (Fig. 30).
Fig.30BEARINGINSTALLER
1 - INSTALLER 2 - HANDLE
(3) Install a new axle shaft seal with Installer
8694 and Handle C-4171.
(4) Lubricate seal lip with gear lubricant. (5) Insert axle shaft through seal, bearing and engage it into side gear splines. Push firmly on the axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal lip.
DR PINION SEAL (Continued)
FRONT AXLE - C205F
3 - 35
Fig.32PINIONROTATINGTORQUE
1 - COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH
Fig.34PINIONSEALINSTALLER
1 - HANDLE 2 - INSTALLER
(4) 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.
(5) Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play (Fig. 35).
CAUTION: Do not exceed 271 N·m (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Damage to the col- lapsible spacer or bearings may result.
Fig.33COMPANIONFLANGEREMOVER
1 - COMPANION FLANGE 2 - PULLER TOOL
INSTALLATION
(1) Apply a light coating of gear lubricant on the
(2) Install seal with Installer 8695 and Handle
lip of pinion seal.
C-4171 (Fig. 34).
(3) Install companion flange onto the pinion with
Installer C-3718 and Holder 6719A.
Fig.35COMPANIONFLANGEHOLDER
1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH
3 - 36
FRONT AXLE - C205F PINION SEAL (Continued)CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
(6) Record pinion rotating torque using an inch pound torque wrench. The rotating torque should be equal to the reading recorded during removal plus an additional 0.56 N·m (5 in. lbs.) (Fig. 36).
DR
DIFFERENTIAL DESCRIPTION
The differential case is a one-piece design. The dif- ferential pinion shaft is retained with a snap ring. Differential bearing preload and ring gear backlash is adjusted by the use of adjusters. The adjuster are between the differential bearings and the differential housing. Pinion bearing preload is set and main- tained by the use of a collapsible spacer. The stamped steel cover provides a means for inspection and servicing the differential.
OPERATION
During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 37).
Fig.36PINIONROTATIONTORQUE
1 - COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH
(7) If rotating torque is low, tighten the pinion nut in 6.8 N·m (5 ft. lbs.) increments until the proper rotating torque is achieved.
lbs.)
CAUTION: If maximum tightening torque 475 N·m (350 ft. to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.
is reached prior
(8) Install propeller shaft with reference marks
aligned.
necessary.
(9) Add gear lubricant to differential housing if
(10) Install half shafts and skid plate if equipped.
Fig.37DIFFERENTIAL-STRAIGHTAHEADDRIVING 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 2 - PINION GEAR 3 - SIDE GEAR 4 - PINION GEARS ROTATE WITH CASE
When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 38). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.
REMOVAL
(1) Remove differential housing cover and drain
fluid.
DR DIFFERENTIAL (Continued)
FRONT AXLE - C205F
3 - 37
(6) Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.(7) Spread the housing to remove the differential case from the housing (Fig. 40). Measure the distance with the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
Fig.38DIFFERENTIAL-ONTURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
(2) Remove axle shafts. (3) Loosen bearing cap bolts.
NOTE: Differential bearing cap reference numbers are stamped on caps and machined flat on the housing. If reference numbers cannot be found, make new marks for later reference.
(4) Install Adapter Plates 8142-A onto the housing. (5) Install Spreader W-129-B onto the adapter plates (Fig. 39) and tighten the turnbuckle finger- tight.
Fig.39ADAPTERPLATESANDSPREADER
1 - ADAPTER PLATE 2 - SPREADER
Fig.40DIALINDICATORLOCATION
1 - DIAL INDICATOR 2 - SPREADER
(8) Remove dial indicator. (9) While holding the differential case in position,
remove bearing cap bolts and caps.
(10) Remove differential
from the housing (Fig. 41). Ensure differential bearing cups and shims remain in position on the differential bearings.
(11) Tag differential bearing cups and shims to
indicate their location.
(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear. (2) Remove roll-pin holding mate shaft in housing. (3) Remove pinion gear mate shaft. (4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 42).
(5) Remove the differential side gears and thrust
washers.
3 - 38
FRONT AXLE - C205F DIFFERENTIAL (Continued)DR
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers. (3) Install pinion gear mate shaft. (4) Align the hole in the pinion gear mate shaft
with the hole in the differential case.
(5) Install the roll-pin in the differential case a punch and hammer (Fig. 43). Peen the edge of the roll-pin hole in the differential case in two places 180° apart.
(6) Lubricate all differential
components with
hypoid gear lubricant. (7) Install ring gear.
Fig.41DIFFERENTIAL
1 - HOUSING 2 - DIFFERENTIAL 3 - BEARING CUPS
Fig.42PINIONMATEGEAR
1 - THRUST WASHER 2 - SIDE GEAR 3 - PINION MATE GEAR
Fig.43PINIONMATESHAFTROLL-PIN
1 - PUNCH 2 - PINION MATE SHAFT 3 - MATE SHAFT LOCKPIN
INSTALLATION
NOTE: If replacement differential bearings or differ- ential case are replaced, Refer to adjustments for Differential Bearing Preload and Gear Backlash pro- cedures.
(1) Install Spreader W-129-B with the Adapter the safety holddown
Plates 8142-A and install clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the opposite side of the housing and zero the indicator.DR DIFFERENTIAL (Continued)
(3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
FRONT AXLE - C205F
3 - 39
(4) Remove dial indicator. (5) Install differential case in the housing. Ensure differential bearing cups remain in position on the bearings and the differential preload shims are seated in the housing. Tap differential case to ensure bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader. (8) Tighten the bearing cap bolts to 61 N·m (45 ft.
lbs.).
(9) Install axle shafts. (10) Apply a bead of red Mopar Silicone Sealant or
equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min- utes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N·m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE BEARINGS REMOVAL
(1) Remove differential from housing. (2) Remove bearings from the differential case with Puller/Press C-293-PA, Adapters C-293-48 and Plug C-293-3 (Fig. 44).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 45).
(2) Install differential into the housing.
Fig.44DIFFERENTIALCASEBEARINGPULLER
1 - PULLER 2 - ADAPTERS 3 - BEARING 4 - DIFFERENTIAL 5 - PLUG
Fig.45DIFFERENTIALCASEBEARINGS
1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER
3 - 40
FRONT AXLE - C205F
DR
PINION GEAR/RING GEAR REMOVAL
NOTE: The ring gear and pinion are serviced in a matched set. Never replace one without replacing the other.
(1) Remove differential from housing. (2) Place differential case in a vise with soft jaw
(3) Remove bolts holding ring gear to differential
(Fig. 46).
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 46).
Fig.47PINIONROTATINGTORQUE
1 - PINION COMPANION FLANGE 2 - TORQUE WRENCH
Fig.48COMPANIONFLANGEREMOVER
1 - COMPANION FLANGE 2 - PULLER TOOL
(15) Remove oil slinger, if equipped and front pin-
ion bearing.
(16) Remove
front
pinion bearing
cup with
Remover 8831 and Handle C-4171 (Fig. 49).
(17) Remove rear pinion bearing cup from housing
(Fig. 50) with Remover 8401 and Handle C-4171.
Fig.46RINGGEAR
1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - RAWHIDE HAMMER
(5) Mark the companion yoke and companion
flange for installation reference.
(6) Remove companion flange bolts and tie the pro-
peller shaft to the vehicle underbody.
(7) Rotate companion flange three or four times
and verify flange rotates smoothly.
(8) Record pinion rotating torque an inch pound
torque wrench for installation reference (Fig. 47).
(9) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(10) Position Holder 6719 against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so that the Holder 6719 is held to the flange.
(11) Remove the pinion nut. (12) Remove the companion flange with Remover
C-452 (Fig. 48).
(13) Remove pinion from differential housing. (14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
DR PINION GEAR/RING GEAR (Continued)
FRONT AXLE - C205F
3 - 41
Fig.49FRONTPINIONBEARINGCUP
Fig.51COLLAPSIBLESPACER
1 - HOUSING 2 - REMOVER 3 - HANDLE
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
Fig.50REARPINIONBEARINGCUP
1 - HOUSING 2 - REMOVER 3 - HANDLE
(18) Remove collapsible preload spacer (Fig. 51). (19) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-42 (Fig. 52).
Fig.52REARPINIONBEARING
1 - PULLER 2 - VISE 3 - ADAPTERS 4 - DRIVE PINION GEAR SHAFT
(20) Remove depth shims from the pinion shaft
and record thickness of shims.
FRONT AXLE - C205F
3 - 42
PINION GEAR/RING GEAR (Continued) INSTALLATIONNOTE: The ring gear and pinion are serviced in a matched set. Never replace one gear without replac- ing the other matching gear. If ring and pinion gears or bearings are replaced, Refer to Adjust- ments for Pinion Gear Depth Setting.
DR
(3) Install front pinion bearing cup with Installer 8693 and Handle C-4171 (Fig. 54) and verify cup is seated.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of the bearing cups.
(2) Install rear pinion bearing cup with Installer 8692 and Driver Handle C-4171 (Fig. 53) and verify cup is seated.
Fig.54FRONTPINIONBEARINGCUP
1 - HOUSING 2 - INSTALLER 3 - HANDLE
(4) Lubricate front pinion bearing and install bear-
(5) Apply a light coating of gear lubricant on the
ing in the housing.
lip of pinion seal.
(6) Install pinion seal with Installer 8695 and
Handle C-4171 (Fig. 55).
Fig.53REARPINIONBEARINGCUP
1 - HOUSING 2 - INSTALLER 3 - HANDLE
Fig.55PINIONSEAL
1 - HANDLE 2 - INSTALLER
DR PINION GEAR/RING GEAR (Continued)
FRONT AXLE - C205F
3 - 43
(7) Place pinion depth shim (Fig. 56) on the pinion
shaft.
(9) Install new collapsible spacer onto the pinion
shaft (Fig. 58).
Fig.56PINIONDEPTHSHIM
Fig.58COLLAPSIBLESPACER
1 - PINION DEPTH SHIM 2 - PINION GEAR
(8) Install rear pinion bearing onto the pinion
shaft with Installer 6448 and a press (Fig. 57).
Fig.57REARPINIONBEARING
1 - PRESS 2 - INSTALLER 3 - PINION GEAR 4 - REAR PINION BEARING
1 - COLLAPSIBLE SPACER 2 - REAR PINION BEARING 3 - PINION DEPTH SHIM
(10) Lubricate rear pinion bearing and install the
pinion gear in the housing. companion
(11) Install
C-3718 and Holder 6719.
flange with
Installer
(12) Install new pinion nut and tighten to 271
N·m (200 ft. lbs.) (Fig. 59).
(13) Using Holder 6719 and a torque wrench set at 475 N·m (350 ft. lbs.). Tighten pinion nut until bear- ing end play is taken up.
(14) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) increments until desired rotating torque is achieved. Measure rotating torque frequently to avoid over- crushing the collapsible spacer (Fig. 60). The pinion rotating torque should be: † Original Bearings: 1 to 2.5 N·m (10 to 20 in. lbs.)† New Bearings: 2.0 to 2.8 N·m (18 to 25 in. lbs.)
CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
(15) Invert differential case and start two ring
gear bolts to provide ring gear bolt hole alignment.
(16) Invert differential case in the vise.
FRONT AXLE - C205F
3 - 44
PINION GEAR/RING GEAR (Continued)DR
(17) Install new ring gear bolts and alternately
tighten to 108 N·m (80 ft. lbs.) (Fig. 61).
CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage.
Fig.59PINIONNUT
1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH
Fig.61RINGGEARBOLTS
1 - TORQUE WRENCH 2 - BOLTS 3 - RING GEAR 4 - DIFFERENTIAL CASE
(18) Install differential in housing and verify gear
mesh, backlash and contact pattern.
(19) Install differential cover and fill with gear
lubricant.
Fig.60PINIONROTATINGTORQUE
1 - PINION COMPANION FLANGE 2 - TORQUE WRENCH
DR
FRONT AXLE - 9 1/4 AA
3 - 45
FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page
page
FRONT AXLE - 9 1/4 AA
PINION SEAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 49
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 53
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 53AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 56
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58FRONT AXLE - 9 1/4 AA DESCRIPTION
The axle consists of a cast iron center casting dif- ferential housing with axle shaft tubes extending from each side. The tubes are pressed into the differ- ential housing and welded. The design has the cen- terline of the pinion set above the centerline of the ring gear. The axle has full-floating axle shafts, meaning the shaft are supported by the hub bear- ings. The axle has a vent used to relieve internal pressure caused by lubricant vaporization and inter- nal expansion.
OPERATION
The axle receives power from the front propeller shaft. The propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case. The engine power is transmitted to the axle shafts through the pinion mate and side gears. The side gears are splined to the axle shafts.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri- cant, incorrect backlash, tooth contact, worn/damaged gears or the carrier housing not having the proper offset and squareness.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60DIFFERENTIAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 62
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving condition. These conditions are accelera- tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
