Dodge Nitro. Manual — part 581

DIAGNOSIS AND TESTING

REAR AXLE - 8 1/4

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing not having the proper offset and squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving
condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the
vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise
range. If the noise stops or changes greatly check for:

Insufficient lubricant.

Incorrect ring gear backlash.

Gear damage.

Differential side and pinions gears, usually do not cause noise during straight-ahead driving, when the gears are
unloaded. The side gears are loaded during turns. A worn pinion mate shaft can also cause a snapping or a
knocking noise.

BEARING NOISE

Bearing noise can be either a whining or a growling sound.

Pinion bearings have a constant high pitch noise, because it rotates at a faster rate. This noise changes with
vehicle speed. If noise is heard under a load, the rear pinion bearing is the source. If noise is heard during a
coast, the front pinion bearing is the source.

Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and varies
only with vehicle speed.

Axle shaft bearing noise generally changes when the bearings are loaded. Turn vehicle sharply to the left and
the right during a road test. This will load and unload the bearings and change the noise level. If axle bearing
damage is slight, the noise is usually not noticeable at speeds above 30 m.p.h.

LOW SPEED KNOCK

Low speed knock is generally caused by:

Worn U-joints/CV joint.

Worn side-gear thrust washers.

Worn pinion shaft bore.

2007 Dodge Nitro R/T

2007 DRIVELINE Differential & Driveline - Nitro

VIBRATION

Vibration at the rear of the vehicle is usually caused by:

Damaged drive shaft.

Missing drive shaft balance weight(s).

Worn or out-of-balance wheels.

Loose wheel lug nuts.

Worn U-joints/CV joint.

Loose/broken springs.

Damaged axle shaft bearing(s).

Loose pinion gear nut.

Excessive pinion yoke run out.

Bent axle shaft(s).

Check for loose or damaged front-end components or engine/transmission mounts. These components can
contribute to what appears to be an axle vibration. Also look at engine accessories, brackets and drive belts.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged, can be caused by:

High engine idle speed.

Transmission shift operation.

Loose engine/transmission/transfer case mounts.

Worn U-joints/CV joint.

Loose spring mounts.

Loose pinion gear nut and yoke.

Excessive ring gear backlash.

Excessive side gear to case clearance.

To determined the source of a snap/clunk noise, raise vehicle on a hoist with the wheels free to rotate. Have a
helper shift the transmission into gear and listen for the noise.

DIAGNOSTIC CHART

NOTE:

All driveline components should be examined before starting any repair.

Condition

Possible Causes

Correction

Wheel Noise

1. Wheel loose.

1. Tighten loose nuts.

2. Worn wheel bearing.

2. Replace bearing.

Axle Shaft Noise

1. Misaligned axle tube.

1. Inspect axle tube alignment.
Correct as necessary.

2007 Dodge Nitro R/T

2007 DRIVELINE Differential & Driveline - Nitro

2. Bent or sprung axle shaft.

2. Inspect and correct as
necessary.

Axle Shaft Broke

1. Misaligned axle tube.

1. Replace the broken shaft after
correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid
excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid
or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and
inspect and repair clutch as
necessary.

Differential Cracked

1. Improper adjustment of the
differential bearings.

1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.

Differential Gears Scored

1. Insufficient lubrication.

1. Replace scored gears. Fill
differential with the correct fluid
type and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill
differential with the correct fluid
type and quantity.

3. Excessive spinning of one
wheel/tire.

3. Replace scored gears. Inspect
all gears, pinion bores, and shaft
for damage. Service as necessary.

Loss Of Lubricant

1. Lubricant level too high.

1. Drain lubricant to the correct
level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed. 6. Remove, clean and seal cover.

Axle Overheating

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct
fluid type and quantity.

3. Bearing pre-loads too high.

3. Adjust bearing pre-loads.

4. Insufficient ring gear backlash. 4. Adjust ring gear backlash.

2007 Dodge Nitro R/T

2007 DRIVELINE Differential & Driveline - Nitro

REMOVAL

REAR AXLE - 8 1/4

Gear Teeth Broke

1. Overloading.

1. Replace gears. Examine other
gears and bearings for possible
damage.

2. Erratic clutch operation.

2. Replace gears and examine the
remaining parts for damage.
Avoid erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine
remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine
remaining parts for damage.
Ensure ring gear backlash is
correct.

Axle Noise

1. Insufficient lubricant.

1. Fill differential with the correct
fluid type and quantity.

2. Improper ring gear and pinion
adjustment.

2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.

3. Unmatched ring gear and
pinion.

3. Replace gears with a matched
ring gear and pinion.

4. Worn teeth on ring gear or
pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing pre-
load.

7. Ring gear run-out.

7. Measure ring gear run-out.
Replace components as necessary.

8. Loose differential bearing cap
bolts.

8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
to t specifications.

9. Housing not machined properly. 9. Replace housing.

2007 Dodge Nitro R/T

2007 DRIVELINE Differential & Driveline - Nitro