Dodge Durango (HB). Manual — part 43
ASSEMBLY
NOTE: If same gears and thrust washers are being
used, install them into their original locations.
1. Lubricate all differential components with axle lubri-
cant.
2. Install
differential
side
gears
(2)
and
thrust
washers.
3. Install first pinion gear (3) with thrust washer into
differential window (1) and side gears (2). Rotate
pinion gear into the case.
4. Install remaining pinion gear and thrust washer.
Rotate gears to align hole in the pinion gears with
hole in the differential case.
5. Slide pinion shaft into the case and through the
pinion gears to align the gears.
HB
REAR AXLE - 8 1/4
3 - 99
INSTALLATION
1. Apply a coat of hypoid gear lubricant to differential
bearings, bearing cups and threaded adjusters.
NOTE: Grease can be used to keep the adjusters
in position.
2. Install differential assembly into the housing.
3. Install differential bearing caps in their original loca-
tions.
4. Install bearing cap bolts and tighten upper bolts to
14 N·m (10 ft. lbs.). Tighten lower bolts finger-tight
until the bolt head is seated.
5. Perform differential bearing preload and adjustment
procedure.
6. Tighten bearing cap bolts (2) to 135 N·m (100 ft.
lbs).
7. Install adjuster locks (3) on bearing caps and
tighten bolts to 10 N·m (95 in. lbs.).
8. Install axle shafts.
9. Install differential cover.
BEARINGS-DIFFERENTIAL CASE
REMOVAL
1. Remove differential case.
2. Remove differential bearings with Puller C-293-PA
(1) and Adapters C-293-48 (2) and Plug SP-3289
(5).
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REAR AXLE - 8 1/4
HB
INSTALLATION
1. Install differential side bearings (3) with Installer
C-4340 (4) and Handle C-4171 (1).
2. Install differential case.
GEAR-PINION/RING/TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without
replacing the matching gear.
1. Remove propeller shaft.
2. Remove differential from the axle housing.
3. Place differential case in vise with soft metal jaw
protectors.
4. Remove ring gear bolts and drive ring gear (2) off
differential case with a soft hammer (3).
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REAR AXLE - 8 1/4
3 - 101
5. Install bolts into two of the threaded holes in the
pinion flange 180° apart.
6. Position Holder 6719 against flange and install a
bolt and washer into one of the remaining threaded
holes. Tighten bolts so the Holder 6719 is held to
the flange.
7. Hold flange with Holder 6719 and remove flange
nut and washer.
8. Remove flange (1) with Remover C-452 (2).
9. Remove pinion from housing with a soft hammer
(1).
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REAR AXLE - 8 1/4
HB
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