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Section 5 (Rear Driveline Module): Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
Fig 1: Installing Pinion Head Bearing Cup
GC0083893Courtesy of CHRYSLER GROUP, LLC
  1. Install the pinion head bearing using Installer (special tool #5050A, Installer, Bearing Cup) (3) and Handle (special tool #C-4171, Driver Handle, Universal) (2).
    Fig 2: Installing Outer Pinion Bearing Cup
    GC0083894Courtesy of CHRYSLER GROUP, LLC
  2. Install the outer pinion bearing cup using Installer (special tool #8594, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
    Fig 3: Installing Pinion Bearing
    GC0083895Courtesy of CHRYSLER GROUP, LLC
  3. Install bearing (4) on pinion (3) using Installer (special tool #6052, Installer, Bearing/Seal) (2) and press (1).
    Fig 4: Installing New Collapsible Spacer Onto The Pinion Shaft
    GC0083891Courtesy of CHRYSLER GROUP, LLC
  4. Install a new collapsible spacer (2) onto the pinion shaft (1).
    Fig 5: Installing Pinion Into Housing
    GC0083896Courtesy of CHRYSLER GROUP, LLC
  5. Install the pinion into the housing and place the outer bearing over the pinion.
    Fig 6: Pinion Nut
    GC0083897Courtesy of CHRYSLER GROUP, LLC
  6. Install the pinion nut (1) onto the pinion shaft (3).
    Fig 7: Pinion Nut On And Off
    GC0083887Courtesy of CHRYSLER GROUP, LLC
  7. Using Spline Holder (special tool #9742, Splined Socket) (1) and Socket (special tool #9921, Wrench, Pinion Nut) (2), tighten pinion nut to 74 N.m (54 ft. lbs.).
    Fig 8: Installing Pinion Seal
    GC0083898Courtesy of CHRYSLER GROUP, LLC
  8. Install the pinion seal using Installer (special tool #9931, Installer, Seal) (2) and a hammer (1).
    Fig 9: Installing Side Gears, Shims And Pinion Gears Into Carrier
    GC0083884Courtesy of CHRYSLER GROUP, LLC
  9. Install side gears (2), shims (4) and pinion gears (3) into carrier (1).
  10. Install the pinion gear shaft into the pinion gears and start the roll pin.
    Fig 10: Installing Roll Pin
    GC0083883Courtesy of CHRYSLER GROUP, LLC
  11. Use a pin punch to install the roll pin (1).
    Fig 11: Ring Gear Bolts
    GC0083882Courtesy of CHRYSLER GROUP, LLC
  12. Apply MOPAR© Lock AND Seal Adhesive or an equivalent to the ring gear bolts (1).
  13. Install ring gear (2) onto the carrier.
  14. Install ring gear bolts (1) and tighten to 41 N.m (30 ft. lbs.).
    Fig 12: Installing Ring Gear Side Carrier Bearing
    GC0083899Courtesy of CHRYSLER GROUP, LLC
  15. Press ring gear side (3) carrier bearing (2) onto shaft using Installer (special tool #9643, Installer, Bearing) (1) and press (4).
    Fig 13: Installing Pinion Side Carrier Bearing
    GC0083900Courtesy of CHRYSLER GROUP, LLC
  16. Coat the ring and pinion gears with pattern grease before assembling.
  17. Press pinion gear side (3) carrier bearing (2) onto shaft using Installer (special tool #9643, Installer, Bearing) (1) and press (4).
    Fig 14: Carrier At Rear Axle
    GC0083881Courtesy of CHRYSLER GROUP, LLC
  18. Install measured side shims (3) and carrier (1) into the carrier housing (2).
  19. Apply a bead of MOPAR© AXLE RTV on the case to seal the cover.
    Fig 15: Bolts At Rear Axle
    GC0083880Courtesy of CHRYSLER GROUP, LLC
  20. Install cover onto carrier case.
  21. Tighten cap bolts (2) to 48 N.m (35 ft. lbs.) and tighten cover bolts (1) to 23 N.m (16 ft. lbs.).
  22. Open the window on the cover and do a pattern check of the gears.
    Fig 16: Seal Onto Installer
    GC0083901Courtesy of CHRYSLER GROUP, LLC
  23. Place pinion side axle seal (1) onto Installer (special tool #9893, Installer, Seal) (3) with lip side down (2).
    Fig 17: Installing Pinion Side Seal
    GC0083902Courtesy of CHRYSLER GROUP, LLC
  24. Install pinion side axle seal using Installer (special tool #9893, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
    Fig 18: Seal Onto Installer
    GC0083901Courtesy of CHRYSLER GROUP, LLC
  25. Place pinion side axle seal (1) onto Installer (special tool #9893, Installer, Seal) (3) with lip side down (2).
    Fig 19: Install Ring Gear Side Seal
    GC0083903Courtesy of CHRYSLER GROUP, LLC
  26. Install ring gear side axle seal using Installer (special tool #9893, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
    Fig 20: Electric Clutch At Rear Axle
    GC0083879Courtesy of CHRYSLER GROUP, LLC
  27. Remove all old gasket material on the mating surfaces of the ECC and RDA. Coat the edge face with liquid gasket. Install wave washer.
  28. Install the ECC to the RDA and tighten the bolts to 78 N.m (58 ft. lbs.).
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