Dodge Durango (HB). Manual — part 39
Pinion gear is set too low. Increase pinion gear height,
by increasing pinion depth shim thickness.
Pinion gear is set too high. Decrease pinion height by
decreasing the pinion depth shim thickness.
SIDE GEAR CLEARANCE
When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
1. Install axle shafts and C-locks and pinion mate
shaft.
2. Measure
each
side
gear
clearance.
Insert
a
matched pair of feeler gauge (1) blades between
the side gear (2) and differential housing on oppo-
site sides of the hub.
3. If side gear clearances is no more than 0.005 inch.
Determine if the axle shaft is contacting the pinion
mate shaft. Do not remove the feeler gauges,
inspect the axle shaft with the feeler gauge
inserted behind the side gear. If the end of the
axle shaft is not contacting the pinion mate shaft,
the side gear clearance is acceptable.
4. If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear clearance.
Remove the thrust washer and measure its thickness with a micrometer. Add the washer thickness to the
recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness
of replacement thrust washer.
HB
REAR AXLE - 8 1/4
3 - 83
In some cases, the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted.
The C-lock is preventing the side gear from sliding on the axle shaft.
5. If there is no side gear clearance, remove the C-lock from the axle shaft. Use a micrometer to measure the
thrust washer thickness. Record the thickness and re-install the thrust washer. Assemble the differential case
without the C-lock installed and re-measure the side gear clearance.
6. Compare both clearance measurements. If the difference is less than 0.012 inch (0.305 mm), add clearance
recorded when the C-lock was installed to thrust washer thickness measured. The sum will determine the
required thickness of the replacement thrust washer.
7. If clearance is 0.012 inch (0.305 mm) or greater, both side gears must be replaced (matched set) and the clear-
ance measurements repeated.
8. If clearance (above) continues to be 0.012 inch (0.305 mm) or greater, the case must be replaced.
SPECIFICATIONS
REAR AXLE - 8 1/4
AXLE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Axle Ratio
3.55, 3.92
Differential Case Flange Runout
0.076 mm (0.003 in.)
Differential Case Clearance
0.12 mm (0.005 in.)
Ring Gear Diameter
209.5 mm (8.25 in.)
Ring Gear Backlash
0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout
0.12 mm (0.005 in.)
Pinion Bearing Preload - Original Bearings
1-2 N·m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings
1.7-4 N·m (15-35 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Differential Cover Bolts
44
32
-
Bearing Cap Bolts
135
100
-
Ring Gear Bolts
102
75
-
Pinion Nut Minimum
285
210
-
Adjuster Lock Screw
10
-
95
Pinion Shaft Lock Screw
25
18.5
220
Bell Crank Bolt
217
160
-
3 - 84
REAR AXLE - 8 1/4
HB
SPECIAL TOOLS
PULLER C-293-PA
ADAPTERS C-293-47
ADAPTERS C-293-48
DIAL INDICATOR C-3339
INSTALLER C-3718
INSTALLER C-4076-B
HANDLE C-4735
ADJUSTMENT WRENCH C-4164
HANDLE C-4171
HB
REAR AXLE - 8 1/4
3 - 85
REMOVER C-4307
INSTALLER C-4308
INSTALLER C-4340
INSTALLER C-4345
PULLER C-452
INSTALLER D-130
ADAPTER PLUG SP-3289
REMOVER 6310
INSTALLER 6448
HOLDER 6719A
3 - 86
REAR AXLE - 8 1/4
HB
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