Rear Axle - 9 1/4: Specifications Dodge Durango II

AXLE SPECIFICATIONS

AXLE SPECIFICATIONS CHART

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS CHART

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1. Remove watts link bell crank bolt (2) from differential cover (1).
2. Remove differential cover bolts.
3. Remove cover and drain fluid.

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1. Clean differential cover.
2. Apply a bead of orange Mopar Axle RTV Sealant (1) or equivalent to the cover (2). CAUTION: If cover is hot installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
3. Install cover and tighten bolts in a criss-cross pattern to 44 N.m (32 ft. lbs.).
4. Fill differential with 2.13 L (4.501 pts.) of gear lubricant. CAUTION: Fill differential by volume only, not to the bottom of fill plug.
5. Install fill hole plug.
6. Install watts link bell crank bolt and tighten to 217 N.m (160 ft. lbs.). NOTE: Bell crank bolt has a Loctite(R) patch, a new bolt should be used. If bolt is not available, clean bolt and apply Loctite(R) 242 to the threads.

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1. With vehicle in neutral, position it on a hoist.
2. Remove brake caliper adapter with caliper and remove rotor.
3. Remove differential housing cover and drain lubricant.
4. Rotate differential case, to access pinion mate shaft lock screw (4). Remove screw (4) and pinion mate shaft (1) from differential case.
5. Push axle shaft (2) inward and remove axle shaft C-lock (1).
6. Remove axle shaft.

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1. Lubricate bearing bore and seal lip with gear lubricant.
2. Insert axle shaft (1) through seal (2) and engage into side gear splines.
3. Insert C-lock in end of axle shaft then push axle shaft outward to seat C-lock in side gear.
4. Insert pinion shaft into differential case and through thrust washers and differential pinions.
5. Align hole in shaft with hole in differential case and install lock screw (4) with Loctite(R) on the threads. Tighten lock screw to 25 N.m (220 in. lbs.).
6. Install differential cover and fill with gear lubricant.
7. Install brake rotor and caliper adapter with caliper.

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1. Remove axle shaft.
2. Remove axle shaft seal (1) from end of the axle tube (2) with a pry bar.

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1. Remove any old sealer/burrs from axle tube.
2. Coat new seal lip with axle lubricant and install seal with Installer 9337 (1) and Handle C-4171 (2)
3. Install axle shaft.

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1. Remove axle shaft.
2. Remove axle seal with pry bar.
3. Position bearing Receiver 9338 (1) on axle tube.
4. Insert bearing Remover 6310 (4) with Foot 6310-9 (3) through receiver (2) and bearing (1).
5. Tighten Remove 6310 nut (1) to pull bearing into the receiver (3).

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1. Remove any old sealer/burrs from axle tube.
2. Install axle shaft bearing with Installer 9337 (1) and Handle C-4171 (2). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer.
3. Coat new axle seal lip with axle lubricant and install with Installer 9337 and Handle C-4171.
4. Install axle shaft.

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1. With vehicle in neutral, position it on a hoist.
2. Mark a installation reference line (3) across the pinion flange (3) and propeller shaft flange (4).
3. Remove propeller shaft.
4. Remove brake calipers and rotors to prevent any drag.
5. Rotate pinion flange three or four times and verify flange rotates smoothly.
6. Measure rotating torque of the pinion with a inch pound torque wrench (2) and record reading.
7. Install two bolts into the pinion flange threaded holes, 180° apart. Position Holder 6719A against the flange and install and tighten two bolts and washers into the remaining holes.
8. Hold the flange with Holder 6719A and remove pinion nut and washer.
9. Remove companion flange (1) with Remover C-452 (2).
10. Remove pinion seal with pry tool or slide-hammer mounted screw.

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1. Apply a light coating of gear lubricant on the lip of pinion seal.
2. Install new pinion seal with Installer C-4076-B (3) and Handle C-4735 (1).
3. Install pinion flange on pinion shaft with Installer C-3718.
4. Install two bolts into the threaded holes in the flange, 180° apart.
5. Position Holder 6719 against the flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange.
6. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 N.m (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instruction will result in damage to collapsible spacer or bearings.
7. Hold companion flange with Holder 6719 (2) and tighten pinion nut with a torque set to 285 N.m (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated.
8. Rotate pinion with an inch pound torque wrench (2). Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 N.m (5 in. lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the collapsible spacer
9. If rotating torque is low, use Holder 6719 to hold the companion flange and tighten pinion nut in 6.8 N.m (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 N.m (210 ft. lbs.).
10. Install propeller shaft..

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1. Remove differential cover.
2. Remove axle shafts.
3. Remove ABS sensor from housing.
4. Mark differential housing and bearing caps (3) for installation reference.
5. Remove bearing adjuster lock bolt (3) from bearing caps.
6. Loosen differential bearing cap bolts.
7. Loosen differential bearing adjusters through the axle tubes (1) with Wrench C-4164 (3).
8. Hold differential case while removing bearing caps and adjusters.
9. Remove differential case and tag differential bearing cups and adjusters to indicate location.
10. Clean housing cavity with flushing oil, light engine oil or a lint free cloth. NOTE: Do not use steam, kerosene or gasoline to clean the housing.

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1. Rotate one pinion gear (2) with thrust washer (3) to the differential window (1). Remove gear and thrust washer.
2. Rotate remaining pinion gear (3) with thrust washer (2) to the differential window (1). Remove gear and washer.
3. Remove differential side gears (1) (2) and thrust washers.