Dodge Durango (HB). Manual — part 47
10. Remove shock absorbers (2) from axle bracket
(3).
11. Remove upper control arms (2) from axle brackets
(1).
12. Lower axle and remove coil springs and spring
isolators.
13. Remove lower control arms (2) from axle brackets
(3).
14. Lower axle and remove from vehicle.
HB
REAR AXLE - 9 1/4
3 - 115
INSTALLATION
1. Raise axle and align lower control arms. Install
control arm bolts loose at this time.
2. Install coil springs.
3. Raise axle and align upper control arms. Install
control arm bolts loose at this time.
NOTE: Bell crank bolt has a Loctite
T
patch, a new
bolt should be used. If bolt is not available, clean
bolt and apply Loctite
T
242 to the threads.
4. Install watts link bell crank bolt (2) and tighten to
217 N·m (160 ft. lbs.).
5. Install shock absorbers and tighten nuts to 102
N·m (75 ft. lbs.).
6. Install parking brake and brake components.
7. Install axle vent hose.
8. Install stabilizer bar (2) and center it with equal
spacing on both sides. Tighten bolts to 61 N·m (45
ft. lbs.).
9. Install propeller shaft (2) with reference marks (3)
aligned.
10. Install new companion flange bolts and tighten to
108 N·m (80 ft. lbs.).
NOTE: Companion flange bolts have a Loctite
T
patch, new bolts should be used. If bolts are not
available, clean bolts and apply Loctite
T
242 to the
threads.
11. With vehicle on the ground, tighten upper control
arm bolts to 170 N·m (125 ft. lbs.). Tighten lower
control arm nuts to 230 N·m (170 ft. lbs.).
3 - 116
REAR AXLE - 9 1/4
HB
ADJUSTMENTS
REAR AXLE - 9 1/4
Ring gear and pinion are supplied as matched sets.
Identifying numbers for the ring gear and pinion are
painted onto the pinion gear shaft and the side of the
ring gear. A plus + number, minus – number or zero 0
along with the gear set sequence number 01 to 99 is
on each gear. This first number (1) is the amount in
thousandths of an inch the depth varies from the stan-
dard depth setting of a pinion marked with a zero 0.
The next two numbers (2) are the sequence number
of the gear set. The standard depth provides the best
teeth contact pattern.
Compensation for pinion depth variance is achieved
with select shims (4) located behind the rear pinion
bearing (3).
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
2
4
2
3
2
2
2
1
0
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
0
+0.004
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
1
+0.003
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
2
+0.002
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
3
+0.001
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
4
0
2
0.001
2
0.002
2
0.003
2
0.004
2
0.005
2
0.006
2
0.007
2
0.008
If installing a new gear, note the depth variance number of the original and replacement pinion. Add or subtract this
number from the original depth shim/oil slinger to compensate for the difference in the depth variances. The num-
bers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the
required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth
shim.
Pinion Gear Depth Variance Chart: Note where Old and New Pinion Marking columns intersect. Intersecting figure
represents plus or minus the amount needed.
HB
REAR AXLE - 9 1/4
3 - 117
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups and
pinion bearings installed in the housing. Take mea-
surements with Pinion Gauge Set and Dial Indicator
C-3339 (1).
1. Assemble Pinion Height Block 6739 (1) Pinion
Block 8542 (1) and rear pinion bearing onto Screw
6741.
2. Insert assembled height gauge components, rear
bearing, and screw into the housing through pinion
bearing cups.
3. Install front pinion bearing and Cone-Nut 6740 on
screw. Tighten cone-nut on screw until Torque To
Rotate screw is 1.7 N·m (15 in. Lbs.).
4. Place Arbor Disc 8541 (1) on Arbor D-115-3 (3) in
position in the housing side bearing cradles. Install
differential bearing caps on arbor discs and tighten
cap bolts to 41 N·m (30 ft. lbs.).
3 - 118
REAR AXLE - 9 1/4
HB
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