Replace the ring and pinion gears in the front and/or rear differential to change gear ratio or repair damaged gears.

Warnings

Tools required

Parts

• Ring and pinion gear set (specify ratio) × 1 — Use OEM specification or quality aftermarket
• Differential bearing set × 1 — Use OEM specification
• Pinion bearing set (front and rear) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification - non-reusable
• Crush sleeve or solid spacer × 1 — Use OEM specification
• Ring gear bolts × 10 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Mopar RTV or equivalent
• Gear marking compound × 1 — Use quality marking compound
• Shim kit for pinion depth and carrier preload × 1 — Use OEM specification

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Raise vehicle and support securely on jack stands at frame rails
3. Remove rear wheels
4. Place drain pan under differential
5. Mark driveshaft-to-pinion flange orientation with paint marker
6. Mark driveshaft-to-transfer case flange orientation
7. Allow differential to cool completely if recently driven
8. Gather all specialized tools and verify ring/pinion gear set matches desired ratio

Procedure

1. 1

   Remove driveshaft and drain differential
   Remove the four driveshaft bolts at the pinion flange. Support driveshaft and remove bolts at transfer case end. Remove driveshaft completely. Remove differential cover bolts and carefully pry cover off. Drain gear oil into pan and inspect for metal particles indicating gear damage.
   Torque spec

   Driveshaft Bolts85 Nm (63 lb-ft)

   Differential Cover Bolts39 Nm (29 lb-ft)
2. 2

   Remove axle shafts and carrier assembly
   Remove brake calipers and rotors for clearance. Mark CV joint-to-axle flange orientation. Remove CV joint bolts on both sides. Support CV axles and pull axle shafts inboard to disengage from carrier. Remove carrier bearing cap bolts and mark caps for correct reinstallation. Use case spreader tool to spread housing slightly and remove carrier assembly.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)
3. 3

   Disassemble carrier and remove ring gear
   Mark ring gear orientation to carrier before removal. Remove ring gear bolts (usually left-hand thread). Use brass drift to tap ring gear off carrier. Remove differential cross shaft pin and shaft. Remove side gears and pinion gears, keeping parts organized for inspection.
   ⚠Ring gear bolts are typically left-hand thread. Turn clockwise to loosen.
4. 4

   Remove pinion gear assembly
   Use pinion holding tool to prevent rotation. Mark pinion nut position and count exposed threads for reference. Remove pinion nut (this nut is not reusable). Use appropriate puller to remove pinion flange. Remove pinion seal. Tap pinion shaft out from front, catching rear bearing. Remove front pinion bearing, crush sleeve, and shims. Mark and record all shim locations and thicknesses.
   ℹ️Record pinion nut position and rotating torque before removal for baseline reference during reassembly.
5. 5

   Remove and replace bearing races
   Use bearing race puller or brass drift to remove carrier bearing races from housing. Remove pinion bearing races from housing using bearing race puller. Clean all housing surfaces thoroughly. Use shop press to install new pinion bearing races ensuring they seat completely. Install new carrier bearing races into housing, verifying proper seating with feeler gauge.
   ⚠Bearing races must be fully seated. Incomplete seating will cause incorrect bearing preload and rapid failure.
6. 6

   Set pinion depth
   Install pinion depth setting tool per manufacturer instructions. Use dial indicator to measure pinion depth relative to centerline of carrier bearings. New ring and pinion sets include pinion depth variance number (typically +/- 0.001 to 0.004 inch). Calculate required shim thickness based on variance number and measurement. Install calculated shim behind rear pinion bearing on pinion shaft.
   ⚠Pinion depth is critical for proper gear contact pattern. Verify all measurements multiple times before proceeding.
7. 7

   Install pinion bearings and assemble pinion
   Press new front and rear pinion bearings onto pinion shaft. Install rear bearing with shim into housing. Insert pinion assembly through housing from front. Install new crush sleeve (or measure and install solid spacer if converting). Install front bearing, pinion seal, and pinion flange. Install new pinion nut hand-tight.
   ℹ️Do not reuse crush sleeve. Each installation requires new crush sleeve or recalculated solid spacer.
8. 8

   Set pinion bearing preload
   Using pinion holding tool and torque wrench, gradually tighten pinion nut in small increments. After each increment, rotate pinion several times to seat bearings. Measure pinion rotating torque with inch-pound torque wrench or spring scale. Continue until rotating torque reaches 15-25 inch-pounds for new bearings. Do not exceed specified preload as crush sleeve cannot be loosened.
   ⚠️If pinion preload is exceeded, entire pinion assembly must be disassembled and crush sleeve replaced. Do not attempt to back off pinion nut.
   Torque spec

   Axle Nut281 Nm (207 lb-ft)
9. 9

   Install ring gear on carrier
   Clean carrier and ring gear mating surfaces thoroughly. Heat ring gear to 200-250°F using heat gun or oven to expand for easier installation. Align ring gear to carrier and tap into place with plastic mallet. Install new ring gear bolts and torque in star pattern to manufacturer specification (typically 70-80 lb-ft for Wrangler Dana axles). Allow ring gear to cool completely.
   ⚠Verify ring gear bolts are left-hand thread if applicable to your axle model. Consult service manual.
10. 10

    Set carrier bearing preload and backlash
    Install carrier bearings onto carrier. Place carrier into housing without shims initially. Measure side clearance to determine total shim requirement. Add 0.010 inch to total measurement for bearing preload. Distribute shims to both sides to achieve 0.005-0.008 inch ring gear backlash measured at ring gear with dial indicator. Install carrier bearing caps in marked positions and torque bearing cap bolts to specification.
    ℹ️Backlash must be measured at multiple points around ring gear. Variation should not exceed 0.002 inch.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Check and adjust gear contact pattern
    Apply thin coat of gear marking compound to 8-10 teeth on ring gear. Rotate pinion in both directions while applying resistance. Examine contact pattern on drive and coast sides. Ideal pattern should be centered on tooth face. Adjust pinion depth shims if pattern is too high or low on tooth. Adjust backlash if pattern is too toe or heel. Repeat until pattern is correct.
    ℹ️Gear pattern adjustment requires removing and reinstalling components. This iterative process is normal and critical for longevity.
12. 12

    Final verification and button up differential
    Verify pinion rotating torque remains within specification. Verify ring gear backlash at multiple points. Perform final gear pattern check. Clean all gear marking compound from gears. Apply thin bead of RTV sealant to differential cover mating surface. Install cover and torque bolts in star pattern. Fill differential with specified Mopar 75W-140 synthetic gear lubricant to bottom of fill hole. Install fill plug.
    ℹ️Allow RTV sealant to cure for 1 hour before filling with fluid if using RTV instead of gasket.
    Torque spec

    Differential Cover Bolts39 Nm (29 lb-ft)
13. 13

    Reinstall axle shafts and driveshaft
    Install CV axle shafts into carrier, ensuring full engagement with side gears. Align CV joints to flanges using orientation marks. Install CV joint bolts and torque to specification. Install brake rotors and calipers. Install driveshaft aligning marks at both pinion flange and transfer case. Torque driveshaft bolts to specification. Install wheels and torque lug nuts.
    Torque spec

    CV Joint Bolts71 Nm (52 lb-ft)

    Driveshaft Bolts85 Nm (63 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification using torque wrench
2. Double-check differential fluid level at fill plug with vehicle level
3. Ensure no tools or parts remain in differential housing area
4. Verify driveshaft orientation marks are properly aligned

Verification

• Test drive vehicle at low speed (under 25 mph) for first 15-20 miles to seat gears
• Listen for whining, grinding, or unusual noises indicating improper setup
• Check differential cover and pinion seal for leaks after test drive
• Recheck differential fluid level after test drive when vehicle is level and cool
• Perform highway test drive and verify smooth operation at all speeds
• Re-inspect for leaks after 100 miles and top off fluid if necessary
• New gears require 500 mile break-in period - avoid heavy acceleration or towing

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