Toyota
Jeep Cherokee
 Service Manual
Differential and driveline » 194 RBI axle » Removal and installation
Pinion gear

The ring and pinion gears are serviced in a matched set. Do not replace the pinion gear without replacing the ring gear.

REMOVAL

(1) Remove differential from the axle housing.

(2) Mark pinion yoke and propeller shaft for installation alignment.

(3) Disconnect propeller shaft from pinion yoke.

Using suitable wire, tie propeller shaft to underbody.

(4) Using Holder 6958 to hold yoke, remove the pinion yoke nut and washer.

(5) Using Remover C-452 and Wrench C-3281, remove the pinion yoke from pinion shaft (Fig. 34).

(6) Remove the pinion gear from housing (Fig. 35).

Catch the pinion with your hand to prevent it from falling and being damaged.

Fig. 34 Pinion Yoke Removal
Fig. 34 Pinion Yoke Removal

1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452

Fig. 35 Remove Pinion Gear
Fig. 35 Remove Pinion Gear

1 - RAWHIDE HAMMER

(7) Use a suitable pry tool or a slide hammer mounted screw to remove the pinion shaft seal.

(8) Remove oil slinger, if equipped, and front pinion bearing.

(9) Remove the front pinion bearing cup with Remover C-4345 and Handle C-4171 (Fig. 36).

(10) Remove the rear bearing cup from housing (Fig. 37). Use Remover D-149 and Handle C-4171.

(11) Remove the collapsible preload spacer (Fig.

38).

Fig. 36 Front Bearing Cup Removal
Fig. 36 Front Bearing Cup Removal

1 - REMOVER
2 - HANDLE

Fig. 37 Rear Bearing Cup Removal
Fig. 37 Rear Bearing Cup Removal

1 - DRIVER
2 - HANDLE

(12) Remove the rear bearing from the pinion with Puller/Press C-293-PA and Adapters C-293-40 (Fig.

39).

Place 4 adapter blocks so they do not damage the bearing cage.

Fig. 38 Collapsible Spacer
Fig. 38 Collapsible Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING

Fig. 39 Rear Bearing Removal
Fig. 39 Rear Bearing Removal

1 - SPECIAL TOOL C-293-PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT

(13) Remove the depth shims from the pinion gear shaft. Record the thickness of the depth shims.

INSTALLATION

(1) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(2) Install the pinion rear bearing cup with Installer D-146 and Driver Handle C-4171 (Fig. 40).

Ensure cup is correctly seated.

Fig. 40 Pinion Rear Bearing Cup Installation
Fig. 40 Pinion Rear Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

(3) Apply Mopart Door Ease, or equivalent, stick lubricant to outside surface of bearing cup.

(4) Install the pinion front bearing cup with Installer D-130 and Handle C-4171 (Fig. 41).

(5) Install pinion front bearing, and oil slinger, if equipped.

(6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-3972-A and Handle C-4171 (Fig. 42).

NOTE: Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh. If the factory installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If required, refer to Pinion Gear Depth to select the proper thickness shim before installing rear pinion bearing.

(7) Place the proper thickness depth shim on the pinion gear.

Fig. 41 Pinion Front Bearing Cup Installation
Fig. 41 Pinion Front Bearing Cup Installation

1 - INSTALLER
2 - HANDLE

Fig. 42 Pinion Seal Installation
Fig. 42 Pinion Seal Installation

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3972-A

(8) Install the rear bearing and slinger, if equipped, on the pinion gear with Installer W-262 (Fig. 43).

(9) Install a new collapsible preload spacer on pinion shaft and install pinion gear in housing (Fig. 44).

(10) Install pinion gear in housing.

(11) Install yoke with Installer Screw 8112, Cup 8109, and holder 6958 (Fig. 45).

(12) Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until there is zero bearing end-play.

(13) Tighten the nut to 271 N·m (200 ft. lbs.).

CAUTION: Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque sequence will then have to be repeated.

Fig. 43 Shaft Rear Bearing Installation
Fig. 43 Shaft Rear Bearing Installation

1 - PRESS
2 - INSTALLATION TOOL
3 - DRIVE PINION GEAR
4 - DRIVE PINION GEAR SHAFT REAR BEARING

Fig. 44 Collapsible Preload Spacer
Fig. 44 Collapsible Preload Spacer

1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING

Fig. 45 Pinion Yoke Installation
Fig. 45 Pinion Yoke Installation

1 - PINION YOKE
2 - AXLE HOUSING

(14) Using yoke holder 6958 and a torque wrench set at 474 N·m (350 ft. lbs.), crush collapsible spacer until bearing end play is taken up (Fig. 46).

NOTE: If the spacer requires more than 474 N·m (350 ft. lbs.) torque to crush, the collapsible spacer is defective and must be replaced.

(15) 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. 47).

Fig. 46 Tightening Pinion Nut-Typical
Fig. 46 Tightening Pinion Nut-Typical

1 - SPECIAL TOOL 6958
2 - 1 in. PIPE
3 - 3/4 DRIVE TORQUE WRENCH

(16) Check bearing rotating torque with a (in. lbs.) torque wrench (Fig. 47). The torque necessary to rotate the pinion gear should be:

  •  Original Bearings - 1 to 2 N·m (10 to 20 in. lbs.).
  •  New Bearings - 1.5 to 4 N·m (15 to 35 in. lbs.).

Fig. 47 Check Pinion Gear Rotating Torque
Fig. 47 Check Pinion Gear Rotating Torque

1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH

(17) Install differential in housing.

    More about «Removal and installation»:

    Rear axle

    Pinion shaft seal

    Collapsible spacer

    Axle shaft

    Axle shaft seal and bearing

    Differential

    Differential side bearings

    Ring gear

    Pinion gear

    Final assembly

    Jeep Cherokee Service Manual / Differential and driveline / 194 RBI axle / Removal and installation / Pinion gear

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