Dodge Sprinter. Manual — part 17
ASSEMBLY - DUAL REAR WHEEL
(1) Install lower differential side gear (1) and shim
(Fig. 48).
(2) Install first differential pinions gears (2) with
spherical washers (3) and cross shaft (1) (Fig. 49).
(3) Install upper differential side gear (1) and shim
(2) (Fig. 50).
(4) Install differential cover with location numbers
(1) on differential case (2) aligned (Fig. 51).
Fig. 48 LOWER SIDE GEAR
1 - SIDE GEAR
2 - DIFFERENTIAL CASE
Fig. 49 DIFFERENTIAL PINIONS
1 - CROSS SHAFT
2 - PINION GEAR
3 - WASHER
Fig. 50 UPPER SIDE GEAR
1 - SIDE GEAR
2 - SHIM
Fig. 51 LOCATION NUMBERS
1 - NUMBERS
2 - CASE
3 - 36
REAR AXLE
VA
(5) Install differential cover (2) bolts (1) and tighen
to 45 N·m (33 ft. lbs.) (Fig. 52).
INSTALLATION
(1) Spread the differential housing (1).
CAUTION: Never spread over 0.3 mm (0.011 in). If
the housing is over-spread, it could be distorted or
damaged.
(2) Install differential case (2) into the housing (1)
with bearings, cups (3) and shims (Fig. 53).
(3) Loosely install differential bearing cap bolts.
(4) Remove spreader (2) and adapters (1) from
housing (Fig. 54).
(5) Tighten bearing cap bolts to 70 N·m (52 ft.
lbs.).
(6) Install axle shafts.
(7) Install differential cover and tighten bolts to 65
N·m (48 ft. lbs.).
(8) Fill differential housing with lubricant.
Fig. 52 DIFFERENTIAL COVER
1 - BOLTS
2 - COVER
Fig. 53 DIFFERENTIAL INSTALLATION
1 - HOUSING
2 - DIFFERENTIAL
3 - DIFFERENTIAL BEARINGS
Fig. 54 SPREADER
1 - ADAPTERS
2 - SPREADER
VA
REAR AXLE
3 - 37
BEARINGS - DIFFERENTIAL
CASE
REMOVAL
(1) Remove
differential
bearings
with
Puller
C-293-PA (1), Plug C-293-3 (2) and four Adapters
C-293-37 (3) (Fig. 55).
INSTALLATION
(1) Set differential on Plug C-293-3.
(2) Install
differential
(2)
bearings
(3)
with
Installer 9523 (4) and Handle C-4171 (1) (Fig. 56).
(3) Install differential case in axle.
Fig. 55 CASE BEARING PULLER
1 - PULLER
2 - PLUG
3- ADAPTERS
Fig. 56 DIFFERENTIAL BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3 - 38
REAR AXLE
VA
SEAL - PINION
REMOVAL
(1) Remove wheels.
(2) Push back brake pads and release hand brake.
NOTE: If it is not possible to spin rear axle shafts
manually, detach rear brake cables.
(3) Drain rear axle oil.
NOTE: On dual rear wheel axle remove axle shafts.
(4) Remove propeller shaft.
(5) Spin pinion flange by hand and check axial
play of bearing.
CAUTION: There must not be any thrust bearing
play. If play excess or there are particles (shavings)
in the drained oil, replace gear assembly.
(6) Measure and record torque to rotate the pinion.
(7) Mark pinion position to pinion flange (1) (Fig.
57).
(8) Unlock collared nut.
(9) Hold pinion flange (1) with Flange Wrench
C-3281 and remove nut.
(10) Remove pinion flange (1) from pinion shaft
with Flange Puller 8992 (2) (Fig. 58).
(11) Check sealing surfaces of joint flange for score
marks and replace joint flange if necessary.
(12) Remove pinion seal/seals (1) (Fig. 59).
Fig. 57 COLLARED NUT
1 - PINION FLANGE
2 - COLLARED NUT
Fig. 58 FLANGE PULLER
1 - FLANGE PULLER
2 - PINION FLANGE
Fig. 59 PINION SEALS
1 - SEALS
2 - AXLE
VA
REAR AXLE
3 - 39
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