Dodge Durango (DN). Manual — part 222

CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.

(14) Align the installation reference marks on the

propeller shaft and companion flange and install the
propeller shaft.

(15) Add gear lubricant to the differential housing,

if necessary. Refer to the Lubricant Specifications for
gear lubricant requirements.

(16) Install both C/V driveshafts.
(17) Install skid plate, if equipped.
(18) Lower the vehicle.

AXLE SHAFT

REMOVAL

(1) Raise and support vehicle. Ensure that the

transmission is in neutral.

(2) Remove the necessary C/V driveshaft from

vehicle.

(3) Remove the skid plate, if equipped.
(4) Clean all foreign material from axle seal area.
(5) Install Puller Adapter 8420 onto the axle shaft.
(6) Install Slide Hammer C-3752 to the puller

adapter.

(7) Remove axle shaft. Use care to prevent damage

to axle shaft bearing and seal, which will remain in
axle shaft tube.

(8) Inspect axle shaft seal for leakage or damage.

Replace the seal if there is any question as to its con-
dition.

(9) Inspect roller bearing contact surface on axle

shaft for signs of brinelling, galling and pitting. If
any of these conditions exist, the axle shaft and/or
bearing and seal must be replaced.

INSTALLATION

(1) Lubricate bearing bore and seal lip with gear

lubricant. Insert axle shaft through seal, bearing,
and engage it into side gear splines.

NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.

(2) Push firmly on the axle shaft until the axle

shaft snap-ring passes completely through the side
gear and engages the snap-ring groove.

(3) Check the differential fluid level and add fluid

if necessary. Refer to Lubricant in this group for
lubricant requirements.

(4) Install skid plate, if necessary.
(5) Install C/V driveshaft.
(6) Lower vehicle.

AXLE SHAFT SEAL AND BEARING

REMOVAL

(1) Remove the axle shaft.
(2) Remove the axle shaft seal from the end of the

axle shaft tube with a small pry bar.

Fig. 9 Tighten Pinion Nut

1 – DIFFERENTIAL HOUSING
2 – COMPANION FLANGE HOLDER
3 – TORQUE WRENCH

Fig. 10 Check Pinion Rotation Torque

1 – COMPANION FLANGE
2 – INCH POUND TORQUE WRENCH

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C205F AXLE

DN

REMOVAL AND INSTALLATION (Continued)

NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.

(3) Remove the axle shaft bearing from the axle

tube with Bearing Removal Tool C-4660-A.

(4) Inspect the axle shaft tube bore for roughness

and burrs. Remove as necessary.

INSTALLATION

Do not install the original axle shaft seal.

Always install a new seal.

(1) Wipe the axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 5063

and Handle C–4171.

(3) Install the new axle shaft seal with Installer

8402 and Handle C–4171.

(4) Install the axle shaft.

DIFFERENTIAL

REMOVAL

(1) Raise and support vehicle.
(2) Remove the differential housing cover and

allow fluid to drain.

(3) Remove the axle shafts.
(4) Note

the

installation

reference

numbers

stamped on one of the bearing caps and a machined
flat on the housing next to the sealing surface. If the
reference numbers cannot be found or seen easily,
make new marks for later reference (Fig. 11).

(5) Loosen the differential bearing cap bolts.
(6) Install Adapter Plates 8142-A onto the axle

housing.

(7) Position Spreader W–129–B onto the adapter

plates and install the safety holddown clamps.
Tighten the tool turnbuckle finger–tight.

(8) Install a Pilot Stud L-4438 at the left side of

the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.

CAUTION: Do not spread over 0.34 mm (0.013 in). If
the housing is over–spread, it could be distorted or
damaged.

(9) Spread the housing enough to remove the dif-

ferential case from the housing. Measure the dis-
tance with the dial indicator (Fig. 12).

(10) Remove the dial indicator.
(11) While holding the differential case in position,

remove the differential bearing cap bolts and caps.

(12) Remove the differential from the housing.

Ensure that the differential bearing cups and shims
remain in position on the differential bearings.

(13) Mark or tag the differential bearing cups and

shims to indicate which side of the differential they
were removed from.

(14) Remove spreader from housing.

INSTALLATION

If replacement differential bearings or differential

case are being installed, differential side bearing
shim requirements may change. Refer to the Differ-
ential Bearing Preload and Gear Backlash proce-
dures in this section to determine the proper shim
selection.

Fig. 11 Bearing Cap Identification

1 – REFERENCE NUMBERS

Fig. 12 Spread Axle Housing—Typical

1 – SPECIAL TOOL C-3339
2 – SPECIAL TOOL W-129–B

DN

C205F AXLE

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REMOVAL AND INSTALLATION (Continued)

(1) Position Spreader W–129–B, with the Adapter

Plates 8142-A seated in the locating holes, on the
axle and install the safety holddown clamps. Tighten
the tool turnbuckle finger–tight.

(2) Install a Pilot Stud L-4438 at the left side of

the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.

CAUTION: Do not spread over 0.34 mm (0.013 in). If
the housing is over-spread, it could be distorted or
damaged.

(3) Spread the housing enough to install the differ-

ential case and preload shims in the housing. Mea-
sure the distance with the dial indicator.

(4) Remove the dial indicator.
(5) Install differential case in the housing. Ensure

that the differential bearing cups remain in position
on the differential bearings and the differential pre-
load shims are seated in the housing. Tap the differ-
ential case to ensure the bearings cups are fully
seated in the housing.

(6) Install the bearing caps at their original loca-

tions (Fig. 13).

(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.
(9) Tighten the bearing cap bolts to 61 N·m (45 ft.

lbs.) torque.

(10) Install the axle shafts.
(11) Install the differential housing cover and fill

with the correct lubricant.

DIFFERENTIAL SIDE BEARINGS

REMOVAL

(1) Remove differential from axle housing.

(2) Remove the bearings from the differential case

with Puller/Press C-293-PA, C-293-48 Blocks, and
Plug C-293-3 (Fig. 14).

INSTALLATION

(1) Using Installer 8236, with handle C-4171,

install the differential side bearings (Fig. 15).

(2) Install differential in axle housing.

RING GEAR

NOTE: The ring gear and pinion are service in a
matched set. Do not replace the ring gear without
replacing the pinion.

REMOVAL

(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with

soft metal jaw protectors. (Fig. 16)

(3) Remove bolts holding ring gear to differential

case.

Fig. 13 Bearing Cap Identification

1 – REFERENCE NUMBERS

Fig. 14 Differential Bearing Removal

1 – SPECIAL TOOL C-293-PA
1 – SPECIAL TOOL C-293-48
3 – BEARING
4 – DIFFERENTIAL
5 – SPECIAL TOOL C-293-3

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C205F AXLE

DN

REMOVAL AND INSTALLATION (Continued)

(4) Using a soft hammer, drive ring gear from dif-

ferential case (Fig. 16).

INSTALLATION

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.

(1) Invert the differential case and start two ring

gear bolts. This will provide case-to-ring gear bolt
hole alignment.

(2) Invert the differential case in the vise.
(3) Install new ring gear bolts and alternately

tighten to 95–122 N·m (70–90 ft. lbs.) torque (Fig.
17).

(4) Install differential in axle housing and verify

gear mesh and contact pattern.

PINION GEAR

NOTE: The ring gear and pinion are serviced in a
matched set. Do not replace the pinion without
replacing the ring gear.

REMOVAL

(1) Remove differential from the axle housing.
(2) Mark the companion yoke and companion

flange for installation alignment.

(3) Remove the bolts holding the companion yoke

to the companion flange.

Fig. 15 Install Differential Side Bearings

1 – HANDLE C-4171
2 – DIFFERENTIAL
3 – BEARING
4 – TOOL 8236

Fig. 16 Ring Gear Removal

1 – CASE
2 – RING GEAR
3 – RAWHIDE HAMMER

Fig. 17 Ring Gear Bolt Installation

1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE

DN

C205F AXLE

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REMOVAL AND INSTALLATION (Continued)