Dodge Durango (DN). Manual — part 221

Condition

Possible Causes

Correction

Axle Noise

1. Insufficient lubricant.

1. Fill differential with the correct
fluid type and quantity.

2. Improper ring gear and pinion
adjustment.

2. Check ring gear and pinion
contact pattern.

3. Unmatched ring gear and pinion.

3. Replace gears with a matched
ring gear and pinion.

4. Worn teeth on ring gear and/or
pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing
pre-load.

7. Mis-aligned or sprung ring gear.

7. Measure ring gear run-out.
Replace components as necessary.

8. Loose differential bearing cap
bolts.

8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.

9. Housing not machined properly.

9. Replace housing.

GEAR NOISE

Axle gear noise can be caused by insufficient lubri-

cant, incorrect backlash, tooth contact, worn/damaged
gears, or the carrier housing not having the proper
offset and squareness.

Gear noise usually happens at a specific speed

range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by

driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak–noise range. If the noise stops or changes
greatly:

• Check for insufficient lubricant.

• Incorrect ring gear backlash.

• Gear damage.
Differential side gears and pinions can be checked

by turning the vehicle. They usually do not cause
noise during straight–ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.

BEARING NOISE

The axle shaft, differential and pinion bearings can

all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.

Pinion bearings have a constant–pitch noise. This

noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a

faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.

Worn or damaged differential bearings usually pro-

duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.

Axle shaft bearings produce noise and vibration

when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCK

Low speed knock is generally caused by a worn

U–joint or by worn side–gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.

VIBRATION

Vibration at the rear of the vehicle is usually

caused by a:

• Damaged drive shaft.

• Missing drive shaft balance weight(s).

• Worn or out–of–balance wheels.

• Loose wheel lug nuts.

• Worn U–joint(s).

• Loose/broken springs.

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C205F AXLE

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DIAGNOSIS AND TESTING (Continued)

• Damaged axle shaft bearing(s).

• Loose pinion nut.

• Excessive companion flange run out.

• Bent axle shaft(s).
Check for loose or damaged front–end components

or engine/transmission mounts. These components
can contribute to what appears to be a rear–end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.

All driveline components should be examined

before starting any repair.

Refer to Group 22, Wheels and Tires, for additional

vibration information.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted

into gear (or the clutch engaged), can be caused by:

• High engine idle speed.

• Transmission shift operation.

• Loose engine/transmission/transfer case mounts.

• Worn U–joints.

• Loose spring mounts.

• Loose pinion nut and companion flange.

• Excessive ring gear backlash.

• Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-

mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.

SERVICE PROCEDURES

LUBRICANT CHANGE

(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the

differential housing cover.

(3) Remove the differential housing cover and

drain the lubricant from the housing.

(4) Clean the housing cavity with a flushing oil,

light engine oil or lint free cloth. Do not use water,
steam, kerosene or gasoline for cleaning.

(5) Remove the sealant from the housing and cover

surfaces. Use solvent to clean the mating surfaces.

(6) Apply a bead of Mopar

t Silicone Rubber Seal-

ant, or equivalent, to the housing cover (Fig. 3).

Install the housing cover within 5 minutes

after applying the sealant.

(7) Install the cover and any identification tag.

Tighten the cover bolts in a criss–cross pattern to 23
N·m (17 ft. lbs.) torque.

(8) Refill the differential with Mopar

t Hypoid

Gear Lubricant, or equivalent, to bottom of the fill
plug hole. Refer to the Lubricant Specifications in
this group for the quantity necessary.

(9) Install the fill hole plug and lower the vehicle.

REMOVAL AND INSTALLATION

FRONT AXLE

REMOVAL

(1) Raise and support the vehicle.
(2) Remove the skid plate, if equipped.
(3) Remove skid plate support crossmember, if nec-

essary.

(4) Remove both C/V driveshafts.
(5) Mark the propeller shaft, transfer case, and

pinion companion flange for installation alignment
reference.

(6) Remove the front propeller shaft.
(7) Remove the axle vent tube.
(8) Use an adjustable and movable jack to support

the differential housing.

Fig. 3 Housing Cover With Sealant

1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 5.0mm (3/16”)

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C205F AXLE

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DIAGNOSIS AND TESTING (Continued)

(9) Remove bolts holding the axle to the engine

mounts (Fig. 4).

(10) Remove bolts holding the axle to the pinion

nose bracket (Fig. 5).

(11) Lower the jack and housing.
(12) Remove the axle from vehicle.

INSTALLATION

(1) Raise the axle into position. Loosely install the

bolts and nuts to hold the axle to the engine mounts
and pinion nose bracket.

(2) Tighten all the bolts finger-tight, then tighten

all bolts to 95 N·m (70 ft. lbs.).

(3) Install the axle vent tube.
(4) Align the reference marks on the propeller

shaft, transfer case, and pinion companion flange.

(5) Install propeller shaft.
(6) Install the C/V driveshafts.
(7) Install the skid plate support crossmember, if

necessary.

(8) Install the skid plate, if necessary.
(9) Check differential lubricant level and add

lubricant, if necessary. Refer to Lubricant Specifica-
tions in this group for lubricant requirements.

(10) Remove the supports and lower the vehicle.

PINION SHAFT SEAL

REMOVAL

(1) Raise and support the vehicle.
(2) Remove skid plate, if equipped.
(3) Remove both C/V driveshafts.
(4) Mark the propeller shaft and pinion companion

flange for installation alignment reference.

(5) Remove the front propeller shaft.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to

rotate the pinion with a (in. lbs.) dial-type torque
wrench (Fig. 6). Record the torque reading for instal-
lation reference.

(8) Install socket head bolts into two of the

threaded holes in the companion flange, 180° apart.

(9) Position Holder 6719 against the companion

flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the bolt
and washer so that the Holder 6719 is held to the
flange.

(10) Hold the flange with Holder 6719. Remove the

pinion nut.

(11) Remove the companion flange with Remover

C-452 (Fig. 7).

(12) Using a suitable pry tool, or a slide hammer

mounted screw, remove the pinion seal.

INSTALLATION

(1) Clean the seal contact surface in the housing

bore.

(2) Examine the splines on the pinion shaft for

burrs or wear. Remove any burrs and clean the shaft.

(3) Inspect companion flange for cracks, worn

splines and worn seal contact surface. Replace com-
panion flange if necessary.

Fig. 4 Axle to Engine Mounts Mounting

1 – LEFT ENGINE MOUNT
2 – RIGHT ENGINE MOUNT
3 – FRONT AXLE

Fig. 5 Pinion Nose Bracket Mounting

1 – PINION NOSE BRACKET
2 – FRONT AXLE

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REMOVAL AND INSTALLATION (Continued)

NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.

(4) Apply a light coating of gear lubricant on the

lip of pinion seal.

(5) Install seal with Installer C-3972-A and Handle

C–4171 (Fig. 8).

(6) Install socket head bolts into two of the

threaded holes in the companion flange, 180° apart.

(7) Position Holder 6719 against the companion

flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the bolt
and washer so that the Holder 6719 is held to the
flange.

(8) Seat the companion flange on the pinion shaft

with Installer C-3718 and Holder 6719.

(9) Remove the Installer C-3718 and install the

new pinion nut.

CAUTION: Do not exceed the minimum tightening
torque when installing the companion flange at this
point. Damage to the collapsible spacer or bearings
may result.

(10) Tighten the pinion nut until there is zero

bearing end-play (Fig. 9).

(11) Tighten the nut to 271 N·m (200 ft. lbs.).

CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.

(12) Rotate the pinion shaft using a (in. lbs.)

torque wrench. Rotating torque should be equal to
the reading recorded during removal plus an addi-
tional 0.56 N·m (5 in. lbs.) (Fig. 10).

(13) If the rotating torque is low, use Holder 6719

to hold the companion flange, and tighten the pinion
nut in 6.8 N·m (5 ft. lbs.) increments until the proper
rotating torque is achieved.

Fig. 6 Measure Total Axle Rotating Torque

1 – COMPANION FLANGE
2 – INCH POUND TORQUE WRENCH

Fig. 7 Companion Flange Removal

1 – COMPANION FLANGE
2 – PULLER TOOL

Fig. 8 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

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C205F AXLE

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REMOVAL AND INSTALLATION (Continued)