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(2) W i t h the axle shaft i n place, insert the C-clip
" l o c k " i n t h e recessed groove a t the end o f the axle
shaft. Force the axle shaft o u t w a r d to "seat" t h e C-
clip " l o c k " i n the differential side gear counterbore.
(3) I n s e r t t h e differential p i n i o n gear mate shaft
i n t o t h e case a n d t h r o u g h the t h r u s t washers a n d the
p i n i o n gears. A l i g n t h e hole i n the shaft w i t h t h e
lock screw hole i n the differential case and i n s t a l l
t h e lock screw. T i g h t e n the screw w i t h 19 N»m (14
ft-lbs) torque.
(4) Remove the residual gasket m a t e r i a l from t h e
d i f f e r e n t i a l housing and the cover, thoroughly clean
t h e contact
surfaces
w i t h m i n e r a l spirits (or a n
equivalent solution) and d r y the surfaces
completely.
(5) A p p l y a 1/16-inch t o 3/32-inch (1.6-mm t o 2.4-
m m ) t h i c k "bead" of M O P A R Silicone Rubber Seal-
a n t (or a n equivalent sealant) around the bolt circle
o n t h e housing cover (Fig. 8).
SEALANT
1/16-TO
3/32-INCH
(1.59-TO
38-AAM)
THICK BEAD
DIFFERENTIAL
HOUSING
COVER
(TYPICAL)
J9003-85
Fig. 8 Sealant On Housing Cover
A l l o w t h e s e a l a n t t o " c u r e " f o r f e w m i n u t e s .
I f f o r a n y r e a s o n t h e h o u s i n g c o v e r i s n o t i n -
s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g t h e seal-
a n t , t h e s e a l a n t m u s t b e r e m o v e d a n d
a n o t h e r
" b e a d " o f s e a l a n t a p p l i e d .
(6) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e attaching bolts. I n s t a l l t h e axle
gear r a t i o identification t a g w i t h one of the cover
bolts. T i g h t e n the cover bolts w i t h 47 N*m (35 ft-lbs)
torque.
(7)
I n s t a l l t h e brake d r u m a n d t h e wheel/tire.
T i g h t e n t h e wheel l u g nuts i n the correct sequence
(Fig. 9) w i t h the specified torque for the vehicle (Re-
fer t o Group 2 2 - T i r e s A n d Wheels).
Fig. 9 Wheel Lug Nut Tightening Sequence
(8) Remove t h e supports and raise o r lower t h e
hoist u n t i l the vehicle is level.
(9) Remove the fill hole p l u g a n d fill the differen-
t i a l housing and the axle tubes w i t h l u b r i c a n t (refer
to the Specifications chart for the type and t h e quan-
t i t y ) . I n s t a l l the fill hole plug.
(10) Lower the vehicle and test t h e brakes a n d the
axle for correct operation.
DRIVE PINION GEAR SHAFT SEAL REPLACEMENT
CAUTION; The following procedures for replace-
ment of the drive pinion gear shaft seal must be
used without exception to ensure that the correct
bearing "preload" torque is retained for the drive
pinion gear shaft bearings. If this procedure is not
completely followed, the result can be premature
failure of the rear axle.
REMOVAL
(1) Raise and support the vehicle.
(2) Score i n s t a l l a t i o n alignment reference m a r k s on
the drive shaft, t h e drive shaft f r o n t U-joint, t h e
drive p i n i o n gear shaft (axle) yoke a n d the end of the
drive p i n i o n gear shaft.
(3) Disconnect the drive shaft f r o m t h e drive p i n i o n
gear shaft (axle) yoke and secure i n a n u p r i g h t posi-
t i o n to prevent damage to the f r o n t U-joint.
(4) Remove t h e rear wheels/tires
a n d t h e brake
drums t o prevent any " d r a g " from causing a possible
false bearing "preload" torque
measurement.
(5) Use a Newton-meter or a n inch-pound torque
wrench (e.g., C-685-A) to measure t h e drive p i n i o n
gear shaft bearing "preload" torque. Rotate the drive
p i n i o n gear shaft w i t h the torque w r e n c h and note
(and record) t h e torque indication as t h e wrench
moves t h r o u g h several complete revolutions.
T h i s
m e a s u r e m e n t
i s v e r y
i m p o r t a n t
b e c a u s e t h e
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