Dodge Dakota (R1). Manual — part 229
(8) Install Forcing Screw and tighten screw to 122
N·m (90 ft. lbs.) maximum to compress Belleville
springs in clutch packs (Fig. 46).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 47).
(10) Insert Turning Bar C-4487-4 into the pinion
mate shaft hole in the case (Fig. 48).
(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove
Forcing
Screw,
Step
Plate
and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in correct order during
removal (Fig. 49).
Fig. 46 Compress Belleville Spring
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 47 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 48 Differential Pinion Gear
1 - PINION GEARS
2 - TURNING BAR
Fig. 49 Side Gear & Clutch Pack
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH PACK
3a - 26
REAR AXLE - 216RBI
R1
DIFFERENTIAL - TRAC-LOK (Continued)
(16) Remove differential case from the Holding Fix-
ture. Remove side gear, clutch pack retainer and clutch
pack. Keep plates in correct order during removal.
ASSEMBLY
Lubricate each component with gear lubricant
before assembly.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 50).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(2) Position assembled clutch disc packs on the
side gear hubs.
(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 51). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Position the differential case on the Holding
Fixture 6963-A.
(5) Install lubricated Step Plate C-4487-1 in lower
side gear (Fig. 52).
(6) Install the upper side gear and clutch disc pack
(Fig. 52).
(7) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear.
(8) Install Forcing Screw C-4487-2 and tighten
screw to slightly compress clutch disc.
(9) Place pinion gears in position in side gears and
verify that the pinion mate shaft hole is aligned.
(10) Rotate case with Turning Bar C-4487-4 until
the pinion mate shaft holes in pinion gears align
with holes in case. It may be necessary to slightly
tighten the forcing screw in order to install the pin-
ion gears.
Fig. 50 Clutch Disc Pack
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 51 Clutch Pack & Lower Side Gear
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
Fig. 52 Clutch Pack & Upper Side Gear
1 - UPPER SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE
R1
REAR AXLE - 216RBI
3a - 27
DIFFERENTIAL - TRAC-LOK (Continued)
(11) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(12) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(13) Remove
Forcing
Screw,
Step
Plate
and
Threaded Adapter.
(14) Install pinion gear mate shaft and align holes
in shaft and case.
(15) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(16) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove differential bearings from the case
with Puller C-293-PA and Adapters C-293-42 and
Plug C-293-3 (Fig. 53).
INSTALLATION
(1) Install differential side bearings with Installer
C-4340 and Handle C-4171 (Fig. 54).
(2) Install differential case into housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced in a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Raise and support the vehicle.
(2) Mark pinion yoke and propeller shaft for
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Tie propeller shaft to underbody.
(4) Remove differential from axle housing.
(5) Place differential case in a vise with soft metal
jaw.
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear from the differential case with
a rawhide hammer (Fig. 55).
(8) Hold pinion yoke with Wrench 6958 and
remove pinion yoke nut and washer.
Fig. 53 Differential Bearing Puller
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
Fig. 54 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
3a - 28
REAR AXLE - 216RBI
R1
DIFFERENTIAL - TRAC-LOK (Continued)
(9) Remove pinion yoke from pinion shaft with
Remover C-452 and Wrench C-3281 (Fig. 56).
(10) Remove the pinion gear from housing (Fig.
57).
(11) Remove pinion shaft seal with a pry tool or a
slide hammer mounted screw.
(12) Remove oil slinger, if equipped, and front pin-
ion bearing.
(13) Remove
front
pinion
bearing
cup
with
Remover D-103 and Handle C-4171 (Fig. 58).
Fig. 55 Ring Gear
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 56 Pinion Yoke
1 - FLANGE WRENCH
2 - YOKE
3 - REMOVER
Fig. 57 Pinion Gear
1 - RAWHIDE HAMMER
Fig. 58 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
R1
REAR AXLE - 216RBI
3a - 29
PINION GEAR/RING GEAR (Continued)
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