Dodge Dakota (R1). Manual — part 230
(14) Remove rear bearing cup from housing (Fig.
59) with Remover C-4307 and Handle C-4171.
(15) Remove collapsible preload spacer (Fig. 60).
(16) Remove rear bearing from the pinion shaft
with Puller/Press C-293-PA and Adapters C-293-42
(Fig. 61).
(17) Remove depth shims from the pinion shaft
and record the shims thickness.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If ring gear and pinion are reused, the pinion
depth shim/oil slinger should not require replace-
ment. Refer to Adjustment (Pinion Gear Depth) to
select the proper thickness shim/oil slinger if ring
and pinion gears are replaced.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of pinion bearing cups.
Fig. 59 Rear Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 60 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 61 Rear Pinion Bearing
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3a - 30
REAR AXLE - 216RBI
R1
PINION GEAR/RING GEAR (Continued)
(2) Install
the
pinion
rear
bearing
cup
with
Installer C-4308 and Driver Handle C-4171 (Fig. 62)
and verify cup is seated.
(3) Install pinion front bearing cup with Installer
D-129 and Handle C-4171 (Fig. 63) and verify cup is
seated.
(4) Install pinion front bearing and oil slinger if
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal and install seal with an appropriate
installer (Fig. 64).
(6) Install proper thickness depth shim on the pin-
ion gear.
(7) Install rear bearing and slinger if equipped, on
the pinion gear with Installer 6448 and a press (Fig.
65).
Fig. 62 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 63 Front Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 64 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 65 Rear Pinion Bearing
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION REAR BEARING
R1
REAR AXLE - 216RBI
3a - 31
PINION GEAR/RING GEAR (Continued)
(8) Install a new collapsible preload spacer on pin-
ion shaft and install pinion gear in the housing (Fig.
66).
(9) Install yoke with Installer C3718 and Wrench
6958 (Fig. 67).
(10) Install yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(11) Tighten the nut to 298 N·m (220 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified
preload torque. If preload torque or rotating torque
is exceeded a new collapsible spacer must be
installed.
(12) Using Spanner Wrench 6958 and a torque
wrench set at 380 N·m (280 ft. lbs.), (Fig. 68) slowly
tighten the nut in 6.8 N·m (5 ft. lbs.) increments
until the rotating torque is achieved. Measure the
rotating torque frequently to avoid over crushing the
collapsible spacer (Fig. 69).
NOTE: If more than 380 N·m (280 ft. lbs.) torque is
required to crush the collapsible spacer, the spacer
is defective and must be replaced.
Fig. 66 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
Fig. 67 Pinion Yoke Installer
1 - INSTALLER
2 - YOKE
3 - DIFFERENTIAL HOUSING
4 - WRENCH
Fig. 68 Tightening Pinion Nut
1 - SPANNER WRENCH
2 - 1 in. PIPE
3 - TORQUE WRENCH
3a - 32
REAR AXLE - 216RBI
R1
PINION GEAR/RING GEAR (Continued)
(13) Check bearing rotating torque with a inch
pound torque wrench (Fig. 69). The pinion gear rotat-
ing torque should be:
• Original Bearings: 1 to 2 N·m (10 to 20 in. lbs.)
• New Bearings: 1.7 to 5 N·m (15 to 35 in. lbs.)
(14) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(15) Invert the differential case in the vise.
(16) Install new ring gear bolts (Fig. 70) and alter-
nately tighten to 108 N·m (80 ft. lbs.).
CAUTION: Never reuse ring gear bolts, the bolts
can fracture causing extensive damage.
(17) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Ajustment
(Gear Contact Pattern) for procedure.
(18) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
(19) Install propeller shaft with the reference
marks aligned.
(20) Remove supports and lower vehicle.
Fig. 69 Pinion Rotating Torque
1 - TORQUE WRENCH
2 - PINION YOKE
Fig. 70 Ring Gear
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
R1
REAR AXLE - 216RBI
3a - 33
PINION GEAR/RING GEAR (Continued)
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