Front Axle - C205F: Removal & Installation Dodge Durango II

REMOVAL

1. Remove fill plug.
2. Remove differential cover bolts.
3. Remove cover and drain fluid.

Scheme 46

1. Apply a bead of orange Mopar Axle RTV Sealant (1) or equivalent to the housing cover (2). CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will compromise adhesion quality.
2. Install cover and tighten bolts in a criss-cross pattern to 22.5 N.m (16.5 ft. lbs.).
3. Fill differential with 1.66 L (3.5 pts.) of gear lubricant.
4. Install fill plug.

Scheme 47

1. Remove half shaft from vehicle.
2. Clean axle seal area.
3. Remove snap ring from the axle shaft.
4. Remove axle (1) with Remove 8420A (2) (3) (4) and slide hammer.

INSTALLATION

1. Lubricate bearing bore and seal lip with gear lubricant.
2. Install axle shaft and engage shaft into side gear. Push firmly on axle shaft to engage snap-ring.
3. Check the differential fluid level and add fluid if necessary.
4. Install half shaft.
5. Install skid plate, if necessary.

1. Remove half shaft and axle shaft.
2. Remove axle shaft seal with a small pry bar.

Scheme 48

1. Wipe axle shaft tube bore clean.
2. Install new axle shaft seal with Installer 8402 (1) and Handle C-4171 (2).
3. Install axle shaft and half shaft.

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Scheme 50

1. Remove half shaft, axle shaft and seal.
2. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread the remover in the bearing.
3. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw bearing out.
4. Inspect axle shaft tube bore for roughness and burrs.

Scheme 51

Scheme 52

1. Wipe the axle shaft tube bore clean.
2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2).
3. Install new axle shaft seal with Installer 8402 (1) and Handle C-4171 (2).
4. Install axle shaft and half shaft.

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1. Remove both half shafts.
2. Mark propeller shaft (2) and pinion flange (2) for installation reference.
3. Remove front propeller shaft.
4. Rotate pinion gear three to four times, to verify pinion rotates smoothly.
5. Record pinion flange (1) rotating torque with an inch pound torque wrench (2) for installation reference.
6. Hold flange with Holder 6719 and four bolts and washers.
7. Remove pinion nut.
8. Remove flange (1) with Remover C-452 (2).
9. Remove pinion seal with a pry tool.

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1. Apply a light coating of gear lubricant on the lip of pinion seal.
2. Install seal with Installer C-3972-A (2) and Handle C-4171 (1)
3. Install pinion flange onto the pinion with Installer C-3718 and holder.
4. Hold pinion flange with Holder 6719A (2).
5. Install new pinion nut and tighten nut until there is zero bearing end-play. CAUTION: Do not exceed the minimum tightening torque when installing the companion flange at this point. Damage to the collapsible spacer or bearings may result.
6. Tighten pinion nut to 271 N.m (200 ft. lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new collapsible spacer must be installed.
7. Record pinion flange (1) rotating torque, with a torque wrench (2). Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 N.m (5 in. lbs.).
8. If rotating torque is low, tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until rotating torque is achieved. CAUTION: If maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.
9. Install propeller shaft with reference marks aligned.
10. Install half shafts.

Scheme 59

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Scheme 61

1. Remove. differential housing cover and drain fluid.
2. Remove axle shafts.
3. Loosen bearing cap bolts. NOTE: Differential bearing cap reference numbers are stamped on caps and machined flat on the housing. If reference numbers cannot be found, make new marks for later reference.
4. Install Adapter Plates 8142-A (1) onto the housing.
5. Install Spreader W-129-B (2) onto the adapter plates and tighten the turnbuckle finger-tight.
6. Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339 (1) to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.
7. Spread the housing to remove the differential case from the housing. Measure the distance with the dial indicator. CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged.
8. Remove dial indicator.
9. While holding the differential case in position, remove bearing cap bolts and caps.
10. Remove differential (2) from the housing (1). Ensure differential bearing cups and shims remain in position on the differential bearings.
11. Tag differential bearing cups and shims to indicate their location.
12. Remove spreader from housing.

Scheme 62

1. Remove ring gear.
2. Remove roll-pin holding mate shaft in housing.
3. Remove pinion gear mate shaft.
4. Rotate differential side gears (2) and remove pinion gears (3) and thrust washers (1)
5. Remove differential side gears and thrust washers.

Note. If replacement differential bearings or differential case are replaced, Refer to adjustments for DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH procedures.

Scheme 63

1. Install Spreader W-129-B (1) with the Adapter Plates 8142-A and install the safety holddown clamps. Tighten the tool turnbuckle finger-tight.
2. Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339 (2) to pilot stud. Load indicator plunger against the opposite side of the housing and zero the indicator.
3. Spread housing and measure the distance with the dial indicator. CAUTION: Never spread housing over 0.50 mm (0.020 in). Failure to heed caution may result in damage.
4. Remove dial indicator (1).
5. Install differential case in the housing. Ensure differential bearing cups remain in position on the bearings and the differential preload shims are seated in the housing. Tap differential case to ensure bearings cups are seated in the housing.
6. Install bearing caps to their original locations and loosely install cap bolts.
7. Remove housing spreader (2).
8. Tighten the bearing cap bolts to 61 N.m (45 ft. lbs.).
9. Install axle shafts.
10. Apply a bead of orange Mopar Axle RTV sealant or equivalent to the housing cover. CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to heed caution may result in damage.
11. Install cover and tighten bolts in a criss-cross pattern to 22 N.m (15 ft. lbs.).
12. Fill differential with lubricant.

Scheme 64

1. Remove differential from housing.
2. Remove bearings (3) from differential case (4) with Puller C-293-PA (1) Adapters C-293-48 (2) and Plug C-293-3 (5).

Scheme 65

1. Install differential case bearings (3) with Installer C-3716-A (4) and Handle C-4171 (1).
2. Install differential in axle housing.

Note. The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other matching gear.

Scheme 66

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Scheme 73

1. Remove differential from axle housing.
2. Place differential case in a vise with soft jaw.
3. Remove ring gear bolts.
4. Drive ring gear (2) from differential case (1) with a soft hammer.
5. Remove propeller shaft.
6. Rotate companion flange and verify flange rotates smoothly.
7. Record pinion rotating torque with an inch pound torque wrench (2) 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 that the Holder 6719 is held to the flange.
10. Remove pinion nut.
11. Remove companion flange (1) with Remover C-452 (2).
12. Remove pinion from differential housing with a hammer (1).
13. Remove pinion seal with a pry tool or a slide hammer mounted screw.
14. Remove oil slinger, if equipped, and front pinion bearing.
15. Remove front pinion bearing cup with Remover D-103 (1) and Handle C-4171 (2).
16. Remove rear pinion bearing cup with Remover 8401 (1) and Handle C-4171 (2).
17. Remove collapsible preload spacer (1).
18. Remove rear pinion bearing with Puller C-293-PA (1) and Adapters C-293-42 (3).
19. Remove depth shims from pinion shaft and record shim thickness.

Note. The ring gear and pinion are serviced in a matched set. Never replace one gear without replacing the other. If ring and pinion gears or bearings are replaced, Refer to ADJUSTMENTS for Pinion Gear Depth Setting.

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Scheme 82

1. Apply Mopar Door Ease or equivalent lubricant to outside surface of the bearing cups.
2. Install rear pinion bearing cup with Installer D-145 (1) and Handle C-4171(2).
3. Install front pinion bearing cup with Installer D-129 (1) and Handle C-4171 (2).
4. Install pinion front bearing and oil slinger if equipped.
5. Apply a light coating of gear lubricant on the lip of pinion seal.
6. Install pinion seal with an appropriate installer (2) and handle (1).
7. Place proper thickness depth shim (1) on pinion (2).
8. Install rear bearing (1) on pinion with Installer 6448 (2) and a press (1).
9. Install new collapsible preload spacer (1) onto the pinion.
10. Install pinion gear into housing.
11. Install companion flange with Installer C-3718.
12. Install new pinion nut and tighten to 271 N.m (200 ft. lbs.).
13. With holder (2) and a torque wrench (3) set at 474 N.m (350 ft. lbs.), tighten pinion nut until end play is taken up.
14. Slowly tighten the pinion flange (1) nut in 6,8 N.m (5 ft. lbs.) increments until rotating torque is achieved. Measure rotating torque frequently to avoid overcrushing the collapsible spacer. The pinion rotating torque should be: Original Bearings: 1 to 2.5 N.m (10 to 20 in. lbs.) New Bearings: 1.7 to 2.5 N.m (15 to 22 in. lbs.) CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instructions will damage the collapsible spacer.
15. Invert differential case and start two ring gear bolts. This will provide case-to-ring gear bolt hole alignment.
16. Invert differential case in the vise.
17. Install new ring gear bolts (2) and alternately) tighten to 108 N.m (80 ft. lbs.). CAUTION: Never reuse the ring gear bolts. Failure to follow these instructions will damage bolts.
18. Install differential in axle housing and verify gear mesh and contact pattern.
19. Install differential cover.