Dodge Durango (DN). Manual — part 230
(7) Disconnect the brake hose at the axle junction
block. Do not disconnect the brake hydraulic lines at
the wheel cylinders. Refer to Group 5, Brakes, for
proper procedures.
(8) Disconnect the parking brake cables and cable
brackets.
(9) Disconnect the vent hose from the axle shaft
tube.
(10) Mark the propeller shaft and companion
flange for installation alignment reference.
(11) Remove propeller shaft.
(12) Disconnect shock absorbers from axle.
(13) Remove the spring clamps and spring brack-
ets. Refer to Group 2, Suspension, for proper proce-
dures.
(14) Separate the axle from the vehicle.
INSTALLATION
(1) Raise the axle with lifting device and align to
the leaf spring centering bolts.
(2) Install the spring clamps and spring brackets.
Refer to Group 2, Suspension, for proper procedures.
(3) Install shock absorbers and tighten nuts to 82
N·m (60 ft. lbs.) torque.
(4) Install the RWAL sensor to the differential
housing, if necessary. Refer to Group 5, Brakes, for
proper procedures.
(5) Connect the parking brake cables and cable
brackets.
(6) Install the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(7) Connect the brake hose to the axle junction
block. Refer to Group 5, Brakes, for proper proce-
dures.
(8) Install axle vent hose.
(9) Align propeller shaft and pinion companion
flange reference marks. Install the companion flange
bolts. Tighten to 108 N·m (80 ft. lbs.) torque.
(10) Install the wheels and tires.
(11) Add gear lubricant, if necessary. Refer to
Lubricant Specifications in this section for lubricant
requirements.
(12) Remove lifting device from axle and lower the
vehicle.
AXLE SHAFT
REMOVAL
(1) Raise and support vehicle. Ensure that the
transmission is in neutral.
(2) Remove wheel and tire assembly.
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Clean all foreign material from housing cover
area.
(5) Loosen housing cover bolts. Drain lubricant
from the housing and axle tubes. Remove housing
cover.
(6) Rotate differential case so that pinion mate
shaft lock screw is accessible. Remove lock screw and
pinion mate shaft from differential case (Fig. 10).
(7) Push axle shaft inward and remove axle shaft
C–lock from the axle shaft (Fig. 11).
(8) Remove axle shaft. Use care to prevent damage
to axle shaft bearing and seal, which will remain in
axle tube.
(9) Inspect axle shaft seal for leakage or damage.
(10) 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.
Fig. 10 Pinion Mate Shaft Lock Screw
1 – LOCK SCREW
2 – PINION MATE SHAFT
Fig. 11 Axle Shaft C–Lock
1 – C—LOCK
2 – AXLE SHAFT
3 – SIDE GEAR
3 - 70
8 1/4 AND 9 1/4 AXLE
DN
REMOVAL AND INSTALLATION (Continued)
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) Insert C–lock in end of axle shaft. Push axle
shaft outward to seat C–lock in side gear.
(3) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctite
t on the
threads. Tighten lock screw to 11 N·m (8 ft. lbs.)
torque.
(5) Install cover and add fluid. Refer to Lubricant
Change procedure in this section for procedure and
lubricant requirements.
(6) Install brake drum. Refer to Group 5, Brakes,
for proper procedures.
(7) Install wheel and tire.
(8) Lower vehicle.
8 1/4 AND 9 1/4 AXLE SEAL AND BEARING
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 12).
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 Set 6310, using
Adapter Foot 6310-9 (Fig. 13).
INSTALLATION
NOTE: Do not install the original axle shaft seal.
Always install a new seal.
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install the axle shaft bearing with Installer
C-4198 and Handle C-4171 (Fig. 14). Ensure that the
bearing part number is against the installer. Verify
that the bearing in installed straight and the tool
fully contacts the axle tube when seating the bearing.
(3) Install a new axle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.
Fig. 12 Axle Seal Removal
1 – AXLE TUBE
2 – AXLE SEAL
3 – PRY BAR
Fig. 13 Axle Shaft Bearing Removal Tool
1 – AXLE SHAFT TUBE
2 – NUT
3 – GUIDE PLATE
4 – GUIDE
5 – THREADED ROD
6 – ADAPTER
7 – FOOT
DN
8 1/4 AND 9 1/4 AXLE
3 - 71
REMOVAL AND INSTALLATION (Continued)
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Scribe a mark on the universal joint, compan-
ion flange, and pinion shaft for installation reference.
(3) Disconnect the propeller shaft from the com-
panion flange. Secure the propeller shaft in an
upright position to prevent damage to the rear uni-
versal joint.
(4) Remove the wheel and tire assemblies.
(5) Remove the brake drums to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate the companion flange three or four
times.
(7) Measure the amount of torque necessary to
rotate the pinion with a (in. lbs.) dial-type torque
wrench. Record the torque reading for installation
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 and washer.
(11) Remove the companion flange with Remover
C-452 (Fig. 15).
(12) Remove the pinion seal with suitable pry tool
or slide-hammer mounted screw.
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.
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 the new pinion seal with Installer
C-4076-B and Handle C-4735-1 for 8 1/4 axles (Fig.
16) and Installer C-3860-A and Handle C-4171 for 9
1/4 axles.
NOTE: The seal is correctly installed when the seal
flange contacts the face of the differential housing.
(6) Position the companion flange on the end of the
shaft with the reference marks aligned.
(7) Install socket head bolts into two of the
threaded holes in the companion flange, 180° apart.
(8) 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.
Fig. 14 Axle Shaft Seal and Bearing Installation
1 – HANDLE
2 – INSTALLER
3 – AXLE TUBE
Fig. 15 Companion Flange Removal
1 – COMPANION FLANGE
2 – PULLER TOOL
3 - 72
8 1/4 AND 9 1/4 AXLE
DN
REMOVAL AND INSTALLATION (Continued)
(9) Seat companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(10) Remove the Installer C-3718 and install the
pinion washer and a new pinion nut. The convex side
of the washer must face outward.
CAUTION: Do not exceed the minimum tightening
torque when installing the companion flange retain-
ing nut at this point. Damage to collapsible spacer
or bearings may result.
(11) Hold companion flange with Holder 6719 and
tighten the pinion nut to 285 N·m (210 ft. lbs.) (Fig.
17). Rotate pinion several revolutions to ensure the
bearing rollers are seated.
(12) Rotate the pinion using an (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N·m (5 in. lbs.) (Fig. 18).
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed. The
torque sequence will then have to be repeated.
(13) If the rotating torque is low, use Holder 6719
to hold the companion flange (Fig. 17) and tighten
the pinion nut in 6.8 N·m (5 ft. lbs.) increments until
proper rotating torque is achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(14) The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N·m (210 ft.
lbs.).
Fig. 16 8 1/4 Axle Pinion Seal Installation
1 – SPECIAL TOOL C-4735
2 – DIFFERENTIAL HOUSING
3 – SPECIAL TOOL C-4076-A
Fig. 17 Tightening Pinion Nut
1 – DIFFERENTIAL HOUSING
2 – COMPANION FLANGE HOLDER
3 – TORQUE WRENCH
Fig. 18 Check Pinion Rotation Torque
1 – COMPANION FLANGE
2 – INCH POUND TORQUE WRENCH
DN
8 1/4 AND 9 1/4 AXLE
3 - 73
REMOVAL AND INSTALLATION (Continued)
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