Dodge Durango (DN). Manual — part 232

(13) Remove the rear bearing cup from housing

(Fig. 30). Use:

• Remover C-4307 and Handle C–4171 for the 8

1/4 axle.

• Remover C-4309 and Handle C-4171 for the 9

1/4 axle.

(14) Remove the collapsible preload spacer (Fig.

31).

(15) Remove the rear bearing from the pinion (Fig.

32) with:

• Puller/Press C-293-PA and Adapters C-293-47 for

the 8 1/4 axle.

• Puller/Press C-293-PA and Adapters C-293-37 for

the 9 1/4 axle.

Place 4 adapter blocks so they do not damage

the bearing cage.

(16) Remove the depth shims from the pinion

shaft. Record the thickness of the depth shims.

INSTALLATION

(1) Apply Mopar

t Door Ease, or equivalent, stick

lubricant to outside surface of bearing cup.

(2) Install the pinion rear bearing cup (Fig. 33)

with:

• Installer C-4308 and Driver Handle C–4171 for

the 8 1/4 axle.

• Installer C-4310 and Driver Handle C–4171 for

the 9 1/4 axle.

(2) Ensure cup is correctly seated.
(3) Apply Mopar

t Door Ease, or equivalent, stick

lubricant to outside surface of bearing cup.

Fig. 30 Rear Bearing Cup Removal

1 – DRIVER
2 – HANDLE

Fig. 31 Collapsible Spacer

1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING

Fig. 32 Rear Bearing Removal

1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT

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8 1/4 AND 9 1/4 AXLE

DN

REMOVAL AND INSTALLATION (Continued)

(4) Install the pinion front bearing cup (Fig. 34)

with:

• Installer D–130 and Handle C–4171 for the 8

1/4 axle.

• Installer D–129 and Handle C–4171 for the 9

1/4 axle.

(5) Install pinion front bearing, and oil slinger, if

equipped.

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

lip of pinion seal. Install seal with:

• Installer C-4076–B and Handle C-4735-1 for the

8 1/4 axle (Fig. 35).

• Installer C-3860-A and Handle C-4171 for the 9

1/4 axle.

NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion head to
achieve proper ring gear and pinion mesh. If the
factory installed ring gear and pinion are reused,
the pinion depth shim should not require replace-
ment. If required, refer to Pinion Gear Depth to
select the proper thickness shim before installing
rear pinion bearing.

(7) Place the proper thickness depth shim on the

pinion shaft.

(8) Install

the

rear

bearing

and

slinger,

if

equipped, on the pinion (Fig. 36) with:

• Installer 6448 for the 8 1/4 axle.

• Installer C-3095 for the 9 1/4 axle.
(9) Install a new collapsible preload spacer on pin-

ion shaft and install the pinion in the housing (Fig.
37).

(10) Install the pinion in housing.
(11) Install the companion flange with Installer

C-3718 and Holder 6719.

(12) Install socket head bolts into two of the

threaded holes in the companion flange, 180° apart.

(13) 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. 33 Pinion Rear Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

Fig. 34 Pinion Front Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

Fig. 35 Pinion Seal Installation—8 1/4 Axle

1 – SPECIAL TOOL C-4735
2 – DIFFERENTIAL HOUSING
3 – SPECIAL TOOL C-4076-A

DN

8 1/4 AND 9 1/4 AXLE

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REMOVAL AND INSTALLATION (Continued)

(14) Install the companion flange washer and a

new nut on the pinion and tighten the pinion nut
until there is zero bearing end-play. It will not be
possible at this point to achieve zero bearing end-
play if a new collapsible spacer was installed.

(15) Tighten the nut to 285 N·m (210 ft. lbs.) (Fig.

38).

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.

(16) Using Holder 6719, crush collapsible spacer

until bearing end play is taken up.

(17) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)

increments until the desired rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 39).

(18) Check bearing rotating torque with an inch

pound torque wrench (Fig. 39). The torque necessary
to rotate the pinion should be:

• Original Bearings — 1 to 3 N·m (10 to 20 in.

lbs.).

• New Bearings — 2 to 5 N·m (15 to 35 in. lbs.).
(19) Install propeller shaft.
(20) Install differential in housing.

Fig. 36 Shaft Rear Bearing Installation

1 – PRESS
2 – INSTALLATION TOOL
3 – DRIVE PINION GEAR
4 – DRIVE PINION GEAR SHAFT REAR BEARING

Fig. 37 Collapsible Preload Spacer

1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING

Fig. 38 Tighten the Pinion Nut

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

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8 1/4 AND 9 1/4 AXLE

DN

REMOVAL AND INSTALLATION (Continued)

FINAL ASSEMBLY

(1) Scrape the residual sealant from the housing

and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of Mopar

t Silicone

Rubber Sealant, or equivalent, on the housing cover
(Fig. 40).

Install the housing cover within 5 minutes

after applying the sealant.

(2) Install the cover on the differential with the

attaching bolts. Install the identification tag. Tighten
the cover bolts to 41 N·m (30 ft. lbs.) torque.

CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

(3) Refill the differential housing with gear lubri-

cant. Refer to the Lubricant Specifications section of
this group for the gear lubricant requirements.

(4) Install the fill hole plug.

DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL

DISASSEMBLY

(1) Remove pinion mate shaft lock screw (Fig. 41).
(2) Remove pinion mate shaft.
(3) Rotate the differential side gears and remove

the differential pinion gears and thrust washers (Fig.
42).

Fig. 39 Check pinion Rotating Torque

1 – COMPANION FLANGE
2 – INCH POUND TORQUE WRENCH

Fig. 40 Typical Housing Cover With Sealant

1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)

Fig. 41 Pinion Mate Shaft Lock Screw

1 – LOCK SCREW
2 – PINION MATE SHAFT

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8 1/4 AND 9 1/4 AXLE

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REMOVAL AND INSTALLATION (Continued)