Dodge Dakota (R1). Manual — part 211
AXLE SHAFTS
REMOVAL
(1) Place the transmission in NEUTRAL and raise
and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL) ..
(4) Clean all foreign material from housing cover
area.
(5) Remove the housing cover and drain lubricant.
(6) Rotate differential case to access the pinion
shaft lock screw. Remove lock screw and pinion shaft
from differential case (Fig. 16).
(7) Push axle shaft inward then remove axle shaft
C-lock (Fig. 17).
(8) Remove axle shaft being carefull not to damage
shaft bearing and seal.
(9) Inspect axle shaft seal for leakage or damage.
(10) Inspect axle shaft bearing contact surface for
signs of brinelling, galling and pitting.
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.).
(5) Install cover and fill with gear lubricant.
(6) Install brake drum (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - INSTALLATION)
.
(7) Install wheel and tire assemblies.
(8) Remove support and lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Raise and support vehicle.
(2) Remove axle shaft.
(3) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 18).
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) 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.
(3) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(4) Install the axle shaft.
(5) Check and fill gear lubricant.
(6) Remove support and lower vehicle.
Fig. 16 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 17 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
3 - 62
REAR AXLE - 8 1/4
AN
AXLE BEARINGS
REMOVAL
(1) Raise and support vehicle.
(2) Remove axle shaft.
(3) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 19).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(4) Remove
axle
shaft
bearing
with
Bearing
Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig.
20).
INSTALLATION
(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. Ensure bearing is
installed straight and the tool is in contacts with the
axle tube when seating the bearing.
NOTE: Install bearing with part number against the
installer.
(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.
(6) Check and fill gear lubricant.
(7) Remove support and lower vehicle.
Fig. 18 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 19 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3 - PRY BAR
Fig. 20 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
AN
REAR AXLE - 8 1/4
3 - 63
AXLE SHAFT SEALS (Continued)
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, companion flange and
pinion shaft for installation reference.
(3) Remove companion flange bolts and secure the
shaft in an upright position to prevent damage to the
rear universal joint.
(4) Remove the wheel and tire assemblies.
(5) Remove brake drums to prevent any drag.
(6) Rotate companion flange three or four times
and verify flange rotates smoothly.
(7) Measure rotating torque of the pinion with a
inch pound torque wrench and record the reading for
installation reference.
(8) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(9) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(10) Remove the pinion nut and washer.
(11) Remove
companion
flange
with
Remover
C-452 (Fig. 21).
(12) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
INSTALLATION
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant.
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install new pinion seal with Installer C-4076-B
and Handle C-4735-1 (Fig. 22)
(3) Install companion flange on the end of the
shaft with the reference marks aligned.
(4) Install bolts into two of the threaded holes in
the companion flange 180° apart.
(5) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so
Holder 6719 is held to the flange.
(6) Install companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Install the pinion washer and a new pinion
nut. The convex side of the washer must face out-
ward.
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.
(8) Hold companion flange with Holder 6719 and
tighten the pinion nut to 285 N·m (210 ft. lbs.) (Fig.
23). Rotate pinion several revolutions to ensure the
bearing rollers are seated.
(9) Rotate pinion with an inch pound torque
wrench. Rotating torque should be equal to the read-
Fig. 21 Companion Flange
1 - COMPANION FLANGE
2 - PULLER
Fig. 22 Pinion Seal Installer
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
3 - 64
REAR AXLE - 8 1/4
AN
ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 24).
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.
(10) If rotating torque is low use Holder 6719 to
hold the companion flange (Fig. 23) and tighten pin-
ion nut in 6.8 N·m (5 ft. lbs.) increments until proper
rotating torque is achieved.
NOTE: The seal replacement is unacceptable if final
pinion nut torque is less than 285 N·m (210 ft. lbs.).
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.
(11) Install propeller shaft with the installation
reference marks aligned.
(12) Tighten companion flange bolts to 108 N·m
(80 ft. lbs.).
(13) Install the brake drums.
(14) Check the differential housing lubricant level.
(15) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support 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 axle shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark the differential housing and bearing caps
for installation reference (Fig. 25).
(7) Remove bearing threaded adjuster locks from
each bearing cap.
(8) Loosen bearing cap bolts, them loosen the
threaded adjusters with Wrench C-4164 (Fig. 26).
(9) Hold the differential case while removing bear-
ing caps and adjusters.
(10) Remove the differential case.
NOTE: Tag bearing cups and threaded adjusters
location, for installation reference.
Fig. 23 Tightening Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 24 Pinion Rotation Torque
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
AN
REAR AXLE - 8 1/4
3 - 65
PINION SEAL (Continued)
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