Replacing Ring-& Pinion Gears - Layin' Track(s)

Next, install the pinion bearing races. If you don't have a race installer, a brass punch can be used; just be careful and take your time.

Slide the pinion gear into the housing. At first, until you get the pinion depth set up, you will not want to install the seal. To set the depth and bearing preload, install the pinion gear, slide the new crush sleeve and bearing in from the front, and install the yoke and nut.

Tighten the nut to approximately 200 lb-ft to crush the sleeve and set distance for bearing preload. Next, loosen the nut until you get approximately 20-inch pounds of resistance when you spin the yoke. Make sure all bearings are coated with oil before you start to set up preload. After depth is set, remove the yoke and install the seal.

With the pinion FINALLY set to spec, the differential can be installed. To get it close to the factory required spec, follow this procedure. Make sure adjusters are turned out so the differential can be installed. Put the differential in place, and install the bearing caps finger tight. Next, tighten the top bolt of the bearing caps to 10 lb-ft. Now adjust the driver side bearing adjuster so that there is approximately 3-6-thousands of endplay in the gears. Tighten the other side adjuster. That is the basic placement; now for setup.

Now with the dial indicator attached to the rear, proper backlash can be set. Adjust the bearing adjuster on the driver's and passenger's side a little at a time until proper final backlash is set.

This should be 6-8-thousands of an inch. Once final backlash is achieved, tighten the bearing adjusters to 75 lb-ft. and recheck backlash.

With backlash achieved, it's time to check for gear mesh pattern. White marking compound is applied to the ring gear in three different locations, and the pinion is turned to rotate the ring gear, leaving an impression in the marking compound. By reading the guidelines in the instruction manual, you can see if your pattern is acceptable or not, and adjust the pinion shims as necessary. This may take several tries to get it right, but taking the time is worth it. It took us a couple attempts.

Once backlash and the gear mesh is finally set, torque the bearing caps to 100 lb-ft.

We also replaced the axle bearings and seal

To make sure the bearing adjusters stay in place, Mopar uses these little metal tabs that bolt to the caps. Next, slide the axles back into place and reinstall the C-clips and axle pin.

Reinstall the cover, and fill with fluid. We chose Royal Purple synthetic 75-80 Max-Gear lube. Max-Gear is recommended for automotive differentials and manual transmissions. Max-Gear is a tough, high-performance, GL-5 automotive gear oil designed to provide maximum protection to heavily loaded gears. Max-Gear also has hypoid friction modifiers for clutch or cone-style differentials already blended in the mix. This means you don't need to buy that also.