Dodge Dakota (R1). Manual — part 206
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from axle housing.
(2) Place differential case in a vise with soft jaw
(Fig. 30).
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 30).
(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 the companion flange three or four
times and verify flange rotates smoothly.
(8) Record rotating torque of the companion flange
with an inch pound torque wrench for installation
reference (Fig. 31).
(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. 32).
Fig. 29 Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 30 Ring Gear
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 31 Pinion Rotating Torque
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
3 - 42
FRONT AXLE - C205F
AN
DIFFERENTIAL CASE BEARINGS (Continued)
(13) Remove pinion from differential housing (Fig.
33).
(14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
(15) Remove oil slinger, if equipped, and front pin-
ion bearing.
(16) Remove
front
pinion
bearing
cup
with
Remover D-103 and Handle C-4171 (Fig. 34).
(17) Remove rear bearing cup from housing (Fig.
35) with Remover 8401 and Handle C-4171.
Fig. 32 Companion Flange Remover
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 33 Remove Pinion
1 - RAWHIDE HAMMER
Fig. 34 Front Bearing Cup
1 - REMOVER
2 - HANDLE
Fig. 35 Rear Bearing Cup
1 - DRIVER
2 - HANDLE
AN
FRONT AXLE - C205F
3 - 43
PINION GEAR/RING GEAR/TONE RING (Continued)
(18) Remove the collapsible preload spacer (Fig.
36).
(19) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-42 (Fig. 37).
(20) Remove depth shims from the pinion shaft
and record thickness of shims.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other. If ring and pinion gears or bearings
are replaced, Refer to Adjustments for Pinion Gear
Depth Setting.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of bearing cup.
(2) Install rear pinion bearing cup with Installer
D-145 and Driver Handle C-4171 (Fig. 38) and verify
cup is seated.
(3) Apply Mopar Door Ease or equivalent lubricant
to outside surface of bearing cup.
(4) Install front pinion bearing cup with Installer
D-129 and Handle C-4171 (Fig. 39) and verify cup is
seated.
(5) Install pinion front bearing and oil slinger if
equipped.
(6) Apply a light coating of gear lubricant on the
lip of pinion seal.
Fig. 36 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 37 Rear Pinion Bearing
1 - SPECIAL TOOL C-293–PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
Fig. 38 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
3 - 44
FRONT AXLE - C205F
AN
PINION GEAR/RING GEAR/TONE RING (Continued)
(7) Install pinion seal with Installer C-3972-A and
Handle C-4171 (Fig. 40).
(8) Place the proper thickness depth shim on the
pinion shaft.
(9) Install rear bearing and slinger if equipped,
onto the pinion shaft with Installer 6448 (Fig. 41)and
a press.
(10) Install newcollapsible preload spacer onto the
pinion shaft (Fig. 42).
(11) Install the pinion in the axle housing.
(12) Install the companion flange with Installer
C-3718 and Holder 6719.
(13) Install new pinion nut and tighten to 271 N·m
(200 ft. lbs.) (Fig. 43).
(14) Using Holder 6719 and a torque wrench set at
474 N·m (350 ft. lbs.). Tighten pinion nut until bear-
ing end play is taken up.
Fig. 39 Front Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 40 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 41 Rear Pinion Bearing
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 42 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION
4 - PINION DEPTH SHIM
5 - REAR BEARING
AN
FRONT AXLE - C205F
3 - 45
PINION GEAR/RING GEAR/TONE RING (Continued)
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