Dodge Durango (DN). Manual — part 237

(2) Measure each side gear clearance. Insert a

matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 82).

(3) If side gear clearances is no more than 0.005

inch. Determine if the axle shaft is contacting the
pinion mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. If the end of
the axle shaft is not contacting the pinion mate
shaft, the side gear clearance is acceptable.

(4) If clearance is more than 0.005 inch (axle shaft

not contacting mate shaft), record the side gear clear-
ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick-
ness to the recorded side gear clearance. The sum of
gear clearance and washer thickness will determine
required thickness of replacement thrust washer
(Fig. 83).

In some cases, the end of the axle shaft will move

and contact the mate shaft when the feeler gauge is
inserted. The C-lock is preventing the side gear from
sliding on the axle shaft.

(5) If there is no side gear clearance, remove the

C-lock from the axle shaft. Use a micrometer to mea-
sure the thrust washer thickness. Record the thick-
ness and re-install the thrust washer. Assemble the

differential case without the C-lock installed and re-
measure the side gear clearance.

(6) Compare both clearance measurements. If the

difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-lock was installed to
thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.

(7) If clearance is 0.012 inch (0.305 mm) or

greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.

(8) If clearance (above) continues to be 0.012 inch

(0.305 mm) or greater, the case must be replaced.

SPECIFICATIONS

8 1/4 INCH AXLE

Axle Type . . . . . . . . . . . . . . . Semi-floating, hypoid
Lubricant . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capacity . . . . . . . . . . . . . . . . 2.22 L (4.7 pts.)
Trac-Lok Additive . . . . . . . . . . . . . . . 148 ml (5 oz.)
Axle Ratio . . . . . . . . . . . . . . . . . . . . 3.21, 3.55, 3.92
Differential
Case Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Case Flange Runout . . . . . . . . 0.076 mm (0.003 in.)
Ring Gear
Diameter . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 in.)
Backlash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 in.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
Pinion Bearing Preload
Original . . . . . . . . . . . . . . . . 1-2 N·m (10-20 in.lbs.)
New . . . . . . . . . . . . . . . . . . . 2-5 N·m (15-35 in.lbs.)

9 1/4 INCH AXLE

Axle Type . . . . . . . . . . . . . . . Semi-floating, hypoid
Lubricant . . . . . . . . . . . . . . . . . . . . . . SAE 75W-90
Lube Capacity . . . . . . . . . . . . . . . . 2.32 L (4.9 pts.)
Trac-lok Additive . . . . . . . . . . . . . . . . 148 ml (5 oz.)
Axle Ratio . . . . . . . . . . . . . . . . . . . . 3.21, 3.55, 3.92
Differential
Case Flange Runout . . . . . . . . 0.076 mm (0.003 in.)
Ring gear
Diameter . . . . . . . . . . . . . . . . . . 23.50 cm (9.25 in.)
Backlash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 in.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
Pinion Bearing Preload
Original . . . . . . . . . . . . . . . . 1-2 N·m (10-20 in.lbs.)
New . . . . . . . . . . . . . . . . . . 2–5 N·m (15–35 in. lbs.)

Fig. 82 Side Gear Clearance Measurement

1 – FEELER GAUGE BLADES
2 – SIDE GEAR

Fig. 83 Side Gear Calculations

3 - 98

8 1/4 AND 9 1/4 AXLE

DN

ADJUSTMENTS (Continued)

8 1/4 and 9 1/4 INCH AXLE

DESCRIPTION

TORQUE

Diff. Cover Bolt . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bearing Cap Bolt—8 1/4 Axle . . 95 N·m (70 ft. lbs.)
Bearing Cap Bolt—9 1/4 Axle . . . . . . . . . . 136 N·m

(100 ft. lbs.)

Pinion Nut . . . . . . . . . . . . . . . 285 N·m (210 ft. lbs.)
Ring Gear Bolt—8 1/4 Axle . . . 102 N·m (75 ft. lbs.)
Ring Gear Bolt—9 1/4 Axle . . 157 N·m (115 ft. lbs.)
Backing Plate Bolt . . . . . . . . . . 64 N·m (48 ft. lbs.)
RWAL/ABS Sensor Bolt . . . . . . 24 N·m (18. ft. lbs.)
Threaded Adjuster Lock Screw . . 10 N·m (90 in. lbs.)

SPECIAL TOOLS

8 1/4 AND 9 1/4 AXLES

Puller, Hub—6790

Remover, Bearing—6310

Installer—C-4198

Handle—C-4171

Installer—C-4076-B

Handle—C-4735-1

Remover—C-4828

DN

8 1/4 AND 9 1/4 AXLE

3 - 99

SPECIFICATIONS (Continued)

Installer—C-4826

Holder—6719

Puller—C-452

Installer—C-3860-A

Installer—C-3718

Adjustment Rod—C-4164

Puller/Press—C-293–PA

Adapters—C-293-48

Plug—SP-3289

Adapters—C-293-47

3 - 100

8 1/4 AND 9 1/4 AXLE

DN

SPECIAL TOOLS (Continued)

Plug—C-293-3

Installer—C-4340

Installer—C-4213

Holder—8136

Holder—8138

Installer—C-4345

Remover—C-4307

Remover—C-4309

Adapters—C-293-37

Installer—C-4308

DN

8 1/4 AND 9 1/4 AXLE

3 - 101

SPECIAL TOOLS (Continued)