Dodge Durango (DN). Manual — part 224

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. 32).

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 23 N·m (17 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 ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft (Fig. 33).
(4) Rotate the differential side gears and remove

the pinion mate gears and thrust washers (Fig. 34).

(5) Remove the differential side gears and thrust

washers.

ASSEMBLY

(1) Install the differential side gears and thrust

washers.

(2) Install the pinion mate gears and thrust wash-

ers.

(3) Install the pinion gear mate shaft.

Fig. 31 Check Pinion Rotating Torque

1 – COMPANION FLANGE
2 – INCH POUND TORQUE WRENCH

Fig. 32 Typical Housing Cover With Sealant

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

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C205F AXLE

DN

REMOVAL AND INSTALLATION (Continued)

(4) Align the hole in the pinion gear mate shaft

with the hole in the differential case.

(5) Install and seat the pinion mate shaft roll-pin

in the differential case and mate shaft with a punch
and hammer (Fig. 35). Peen the edge of the roll-pin
hole in the differential case slightly in two places,
180° apart.

(6) Lubricate

all

differential

components

with

hypoid gear lubricant.

(7) Install ring gear.

CLEANING AND INSPECTION

AXLE COMPONENTS

Wash differential components with cleaning solvent

and dry with compressed air. Do not steam clean
the differential components.

Wash bearings with solvent and towel dry, or dry

with compressed air. DO NOT spin bearings with
compressed

air.

Cup

and

bearing

must

be

replaced as matched sets only.

Clean axle shaft tubes and oil channels in housing.
Inspect for;
• Smooth appearance with no broken/dented sur-

faces on the bearing rollers or the roller contact sur-
faces.

• Bearing cups must not be distorted or cracked.

• Machined surfaces should be smooth and with-

out any raised edges.

• Raised metal on shoulders of cup bores should

be removed with a hand stone.

• Wear and damage to pinion gear mate shaft,

pinion gears, side gears and thrust washers. Replace
as a matched set only.

• Ring gear and pinion for worn and chipped

teeth.

Fig. 33 Pinion Mate Shaft Removal

1 – PINION MATE GEAR
2 – PINION MATE SHAFT
3 – SIDE GEAR
4 – DRIFT

Fig. 34 Pinion Mate Gear Removal

1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR

Fig. 35 Pinion Mate Shaft Roll-Pin Installation

1 – PUNCH
2 – PINION MATE SHAFT
3 – MATE SHAFT LOCKPIN

DN

C205F AXLE

3 - 47

DISASSEMBLY AND ASSEMBLY (Continued)

• Ring gear for damaged bolt threads. Replaced as

a matched set only.

• Companion flange for cracks, worn splines, pit-

ted areas, and a rough/corroded seal contact surface.
Repair or replace as necessary.

• Preload shims for damage and distortion. Install

new shims, if necessary.

ADJUSTMENTS

PINION GEAR DEPTH

GENERAL INFORMATION

Ring gear and pinion are supplied as matched sets

only. The identifying numbers for the ring gear and
pinion are painted onto the pinion gear shaft (Fig.
36) and the side of the ring gear. A plus (+) number,
minus (–) number or zero (0) along with the gear set
sequence number (01 to 99) is on each gear. This first
number is the amount (in thousandths of an inch)
the depth varies from the standard depth setting of a
pinion marked with a (0). The next two numbers are
the sequence number of the gear set. The standard
setting from the center line of the ring gear to the
back face of the pinion is 99.690 mm (3.925 in.). The
standard depth provides the best teeth contact pat-
tern. Refer to Backlash and Contact Pattern Analysis
Paragraph in this section for additional information.

Compensation

for

pinion

depth

variance

is

achieved with select shims. The shims are placed
between the rear pinion bearing cone and the pinion
gear head (Fig. 37).

If a new gear set is being installed, note the depth

variance marked on both the original and replace-
ment pinion. Add or subtract the thickness of the

original depth shims to compensate for the difference
in the depth variances. Refer to the Depth Variance
charts.

Note where Old and New Pinion Marking columns

intersect.

Intersecting

figure

represents

plus

or

minus amount needed.

Note the painted number on the shaft of the drive

pinion (–1, –2, 0, +1, +2, etc.). The numbers repre-
sent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shim(s). If the num-
ber is positive, subtract that value from the thickness
of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance
Chart.

PINION DEPTH MEASUREMENT AND ADJUSTMENT

Measurements are taken with pinion cups and pin-

ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 8177,
Arbor Discs 8541, and Dial Indicator C-3339 (Fig.
38).

(1) Assemble Pinion Height Block 6739, Pinion

Block 8177, and rear pinion bearing onto Screw 6741
(Fig. 38).

(2) Insert assembled height gauge components,

rear bearing and screw into axle housing through the
pinion bearing cups (Fig. 39).

(3) Install front pinion bearing and Cone 6740 onto

the screw hand tight (Fig. 38).

Fig. 36 Pinion ID Numbers

1 – VARIANCE NUMBER
2 – SEQUENCE NUMBER

Fig. 37 Shim Locations

1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER

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C205F AXLE

DN

CLEANING AND INSPECTION (Continued)

(4) Place Arbor Discs 8541 on Arbor D-115-3 in

position in axle housing side bearing cradles (Fig.
40). Install differential bearing caps on Arbor Discs
and tighten cap bolts. Refer to the Torque Specifica-
tions in this section.

(5) Assemble Dial Indicator C-3339 into Scooter

Block D-115-2 and secure set screw.

(6) Place Scooter Block/Dial Indicator in position

in axle housing so dial probe and scooter block are
flush against the surface of the pinion height block.
Hold scooter block in place and zero the dial indica-
tor face to the pointer. Tighten dial indicator face
lock screw.

(7) With scooter block still in position against the

pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
Observe how many revolutions counterclockwise the
dial pointer travels (approximately 0.125 in.) to the
out-stop of the dial indicator.

(8) Slide the dial indicator probe across the gap

between the pinion height block and the arbor bar

PINION GEAR DEPTH VARIANCE

Original

Pinion

Gear

Depth

Variance

Replacement Pinion Gear Depth Variance

−4

−3

−2

−1

0

+1

+2

+3

+4

+4

+0.008

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

+3

+0.007

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

−0.001

+2

+0.006

+0.005

+0.004

+0.003

+0.002

+0.001

0

−0.001

−0.002

+1

+0.005

+0.004

+0.003

+0.002

+0.001

0

−0.001

−0.002

−0.003

0

+0.004

+0.003

+0.002

+0.001

0

−0.001

−0.002

−0.003

−0.004

−1

+0.003

+0.002

+0.001

0

−0.001

−0.002

−0.003

−0.004

−0.005

−2

+0.002

+0.001

0

−0.001

−0.002

−0.003

−0.004

−0.005

−0.006

−3

+0.001

0

−0.001

−0.002

−0.003

−0.004

−0.005

−0.006

−0.007

−4

0

−0.001

−0.002

−0.003

−0.004

−0.005

−0.006

−0.007

−0.008

Fig. 38 Pinion Gear Depth Gauge Tools

1 – DIAL INDICATOR
2 – ARBOR
3 – PINION HEIGHT BLOCK
4 – CONE
5 – SCREW
6 – PINION BLOCK
7 – SCOOTER BLOCK
8 – ARBOR DISC

Fig. 39 Pinion Height Block

1 – PINION BLOCK
2 – PINION HEIGHT BLOCK

DN

C205F AXLE

3 - 49

ADJUSTMENTS (Continued)