Chrysler RAM TRUCK 2500 1994 Service Manual page 120

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REAR SUSPENSION AND AXLE 3 - 13
(6) Install the wheel and tire assembly.
(7) Fill the differential with lubricant. Refer to the
Specifications chart for the type and quantity. Install
the fill hole plug.
(8) Remove support and lower vehicle. Test the
brakes and axle for correct operation.
PINION SEAL REPLACEMENT
CAUTION: The following procedures must be used
s o the correct pinion bearing preload torque is re­
tained. If not completely followed, the result can be
failure of the rear axle.
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft i n an upright position to
prevent damage to the rear U-joint.
(4) Remove wheel and tire assemblies, and brake
drums.
Brake drag can cause a false bearing preload
torque measurement.
(5) Use a Newton-meter or an inch-pound torque
wrench to measure the pinion bearing preload. Ro­
tate the pinion shaft several times with the torque
wrench. Note the indicated torque as the wrench is
moved through several revolutions.
This measurement important because, bear­
ing preload torque must be carefully re-ad­
justed after the new seal is installed.
(6) Hold yoke with Holder 6719 and remove the
pinion shaft nut and Belleville washer.
(7) Remove the yoke with Remover C-452 (Fig. 8).
Fig. 8 Yoke Removal
(8) Remove the pinion shaft seal with Puller C-748
and clean seal contact surface i n housing bore (Fig.
9).
C-748
J9403-20
Fig. 9 Pinion Seal Removal
INSTALLATION
(1) Inspect splines on pinion shaft for burrs or
wear, remove any burrs and clean the shaft.
(2) Inspect the pinion yoke for cracks, worn splines
and worn seal contact surface. Repair or replace the
yoke as necessary.
The outer perimeter of the seal is pre-coated
with a special sealant additional sealant is not
required.
(3) Install pinion shaft seal with Installer
C-4109-A and Handle C-4735. Seal is correctly in­
stalled when seal flange contacts face of differential
housing flange.
(4) Install yoke on pinion shaft with the reference
marks aligned.
(5) Seat the yoke on pinion shaft with Installer
W-162D and Holder 6719 (Fig. 10).
(6) Remove tools and install the Belleville washer.
The convex side of the washer must face outward.
(7) Hold yoke with Holder 6719 and tighten the
shaft nut to 285 N-m (210 ft. lbs.) torque (Fig. 11).
Rotate pinion shaft several complete revolutions to
ensure the bearing rollers are seated.
CAUTION: Never loosen the pinion gear nut to de­
crease the pinion gear bearing preload torque. If the
specified preload torque is exceeded, a new col­
lapsible spacer must be installed. The torque s e ­
quence will have to be repeated.
(8) Continue tightening and measuring bearing
preload torque until the torque is the same as origi­
nal measurement. The bearing preload torque
should never exceed 1 N-m (10 in. lbs.) more
than original value.