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Front Axle - C205FD: Component Locations RAM Pickup 2500

Differentials & Drive Axles 70 illustrations ~2763 words

SPECIAL TOOLS

10117 - Installer, Seal (Originally Shipped In Kit Number(s) 10075-CHRYSLER, 10075-DODGE.) 5063 - Installer, Bearing (Originally Shipped In Kit Number(s) 8837, 9975.) 6448A - Installer, Bearing/Gear (Originally Shipped In Kit Number(s) 6947, 8667, 8837, 8867.) 6719A - Holder, Yoke (Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9975.) 6739 - Block, Height (Originally Shipped In Kit Number(s) 6730, 9516A-CAN, 9540, 9541.) 6740 - Cone (Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.) 6741 - Screw (Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.) 6761 - Installer, Ball Joint (Originally Shipped In Kit Number(s) 6745, 8165CC.) 6775 - Kit, Master Pinion Depth 8107 - Shim, Dummy (Originally Shipped In Kit Number(s) 8163, 8163CC, 8164, 8164CC, 8165, 8165CC, 9975.) 8142A - Adapters, Spreader (Originally Shipped In Kit Number(s) 8163, 8660, 8660CC, 8662, 8662CC.) 8177 - Gauge, Pinion Height (Originally Shipped In Kit Number(s) 8555, 8700CC, 9975, 9976.) 8398 - Set, Dummy Bearing (Originally Shipped In Kit Number(s) 8555, 8700CC.) 8401 - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 8653, 8700, 8700CC, 9975, 9976.) 8420-3 - Sleeve, Retaining 8420B - Remover, Shaft (Originally Shipped In Kit Number(s) 8660CC, 8662CC, 8660, 8662, 8664, 8668, 8710, 8710CC.) 8541A - Set, Arbor Disc (Originally Shipped In Kit Number(s) 8555, 9975.) 8692 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8685CC, 8696, 8710, 8837.) 8693 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8685, 8685CC, 8696, 8710, 8712, 8837, 9697, 9698.) 8694 - Installer, Seal (Originally Shipped In Kit Number(s) 8685, 8685CC, 8712, 8837.) 8695 - Installer, Seal (Originally Shipped In Kit Number(s) 8685, 8685CC, 8712, 8837.) 8831 - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 8721, 8721CC, 8843.) 9585 - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 9691.) 9766 - Remover, Bearing (Originally Shipped In Kit Number(s) 9765.) 9767 - Installer, Bearing (Originally Shipped In Kit Number(s) 9765.) 9768 - Remover, Bearing (Originally Shipped In Kit Number(s) 9765.) C-293-3 - Adapter, Bearing/Gear (Originally Shipped In Kit Number(s) 8418, 8837, C-293-M, C-4246-AL, DD-914-CLT-L.) C-293-42 - Block Set, Puller (Originally Shipped In Kit Number(s) 9975.) C-293-48 - Block Set, Puller (Originally Shipped In Kit Number(s) 8418, 8837, C-293-M, DD-914-CLT-L.) C-293-PA - Puller, Press (Originally Shipped In Kit Number(s) 8418, 8837, C-293-M.) C-3288-B - Set, Alignment Pins (Originally Shipped In Kit Number(s) 9975.) C-3339A - Set, Dial Indicator (Originally Shipped In Kit Number(s) 9202.) C-3718 - Installer, Flange (Originally Shipped In Kit Number(s) 8418.) C-3752 - Slide Hammers (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202-CAN, 9202CC.) C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) C-4340 - Installer, Bearing (Originally Shipped In Kit Number(s) 8418, 8659.) C-452 - Puller, Companion Flange C-4660-A - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 9926.) C-637 - Slide Hammer, Universal (Originally Shipped In Kit Number(s) 9202.) D-115-2A - Block, Scooter (Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518, 9519, 9540-SUP, 9541-SUP, 9694, 9926.) D-115-3 - Arbor (Originally Shipped In Kit Number(s) 8667, 9516A-CAN.) L-4438 - Dial Indicator Post MD998412 - Pins, Guide (Originally Shipped In Kit Number(s) 8666, 8667, 8705.) W-129-B - Spreader, Differential (Originally Shipped In Kit Number(s) 9975.) W-262 - Installer, Bearing (Originally Shipped In Kit Number(s) 8418.)

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Scheme 233: SPECIAL TOOLS
Scheme 233: SPECIAL TOOLS

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Scheme 248: REMOVAL
Scheme 248: REMOVAL

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Scheme 249
  1. Remove actuator wiring connector.
  2. Remove actuator (1) bolts (2).
  3. Remove actuator (1) from disconnect pocket (2).

Scheme 250

Scheme 250: INSTALLATION
Scheme 250: INSTALLATION

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Scheme 251
Scheme 251
  1. Clean actuator (1) sealing surface and install new gasket (2) if necessary.
  2. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket.
  3. Install actuator (1) bolts (2) and tighten to 27 N.m (20 ft. lbs.).
  4. Install disconnect actuator wiring connector.
  5. Verify differential fluid level and add fluid if necessary.

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Scheme 252: REMOVAL
Scheme 252: REMOVAL

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Scheme 255
Scheme 255
  1. Remove half shaft from vehicle.
  2. Clean axle seal area.
  3. Remove O-ring (1) and snap ring (2) from axle shaft (3).
  4. Remove axle with Remove (special tool #8420B, Remover, Shaft) (2) (3) Collar (special tool #8420-3, Sleeve, Retaining) (4) and Slide Hammer (special tool #C-3752, Slide Hammers).
  5. Remove axle shaft seal with a seal puller.
  6. Install axle shaft bearing Remover (special tool #C-4660-A, Remover, Bearing Cup) (3) in the bearing (1). Then tighten the nut (2) to spread remover in the bearing.
  7. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut (3) to draw the bearing out.

Scheme 256

Scheme 256: INSTALLATION
Scheme 256: INSTALLATION

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Scheme 257
Scheme 257
  1. Wipe axle shaft bearing bore clean.
  2. Install axle shaft bearing with Installer (special tool #5063, Installer, Bearing) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2). CAUTION: Bearing must be installer with lettering facing outwards. Failure to follow these instructions will damage the bearing.
  3. Install a new axle shaft seal with Installer (special tool #8694, Installer, Seal) (1).
  4. Lubricate seal lip with gear lubricant.
  5. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear.
  6. Install axle shaft (3) O-ring (1) and snap ring (2).
  7. Install half shaft.
  8. Verify differential fluid level and add fluid if necessary.

Scheme 258

Scheme 258: REMOVAL
Scheme 258: REMOVAL
  1. Remove differential from housing.
  2. Remove bearings (3) from differential case (4) with Puller (special tool #C-293-PA, Puller, Press) (1) Adapters (special tool #C-293-48, Block Set, Puller) (2) and Plug (special tool #C-293-3, Adapter, Bearing/Gear) (5).

Scheme 259

Scheme 259: INSTALLATION
Scheme 259: INSTALLATION
  1. Install differential case bearings (3) with (special tool #C-4340, Installer, Bearing) (4) and (special tool #C-4171, Driver Handle, Universal) (1).
  2. Install differential into the housing.

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Scheme 260: REMOVAL
Scheme 260: REMOVAL

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Scheme 262
  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 (special tool #8142A, Adapters, Spreader) (1) onto the housing.
  5. Install Spreader (special tool #W-129-B, Spreader, Differential) (2) onto the adapter plates (1) and tighten the turnbuckle finger-tight.
  6. Install a Pilot Stud (special tool #L-4438, Dial Indicator Post) at the left side of the differential housing. Attach Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator.
  7. Spread housing, while measuring the distance with the dial indicator. CAUTION: Never spread housing over 0.50 mm (0.020 in). Failure to follow these instructions will damage the housing.
  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 (3) and shims remain in position on the differential bearings.
  11. Tag differential bearing cups and shims to indicate location.
  12. Remove spreader from housing.

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Scheme 263: DISASSEMBLY
Scheme 263: DISASSEMBLY

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  1. Remove pinion mate shaft lock roll pin and remove pinion mate shaft (1) with a punch (2) from pinion gears (3).
  2. Rotate one pinion gear (2) with thrust washer (3) to the differential window (1) and remove gear and thrust washer.
  3. Rotate remaining pinion gear (3) with thrust washer (2) to the differential window (1) and remove gear and washer.
  4. Remove differential side gears (1, 2) and thrust washers.

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Scheme 267: ASSEMBLY
Scheme 267: ASSEMBLY

Note. If same gears and thrust washers are being used, install them into their original locations.

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  1. Lubricate all differential components with axle lubricant.
  2. Install differential side gears (2) and thrust washers through differential window (1).
  3. Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2). Rotate pinion gear into the case.
  4. Install remaining pinion gear (2) and thrust washer (3). Rotate gears to align hole in the pinion gears with hole in the differential case.
  5. Slide pinion shaft into the case and through the pinion gears. Install pinion mate shaft roll pin and stake pin in case.

Scheme 270

Scheme 270: INSTALLATION
Scheme 270: INSTALLATION

Note. If differential bearings or differential case are replaced, Refer to appropriate Service Information for Differential Bearing Preload and Gear Backlash procedures.

  1. Install Spreader (special tool #W-129-B, Spreader, Differential) (2) with Adapters (special tool #8142A, Adapters, Spreader) (1) and install the safety hold-down clamps. Tighten spreader turnbuckle finger-tight.
  2. Install Stud (special tool #L-4438, Dial Indicator Post) in the left side of the differential housing. Attach Dial Indicator (special tool #C-3339A, Set, Dial Indicator) to a stud. Load indicator plunger against the opposite side of the housing and zero the indicator.
  3. Spread housing, while measuring the distance with the dial indicator. CAUTION: Never spread housing over 0.50 mm (0.020 in). Failure to follow these instruction will damage the housing.
  4. Remove dial indicator.
  5. Install differential case (2) in the housing (1). Ensure differential bearing cups (3) 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.
  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 follow these instruction will cause a leak.
  11. Install cover and tighten bolts in a criss-cross pattern to 23 N.m (17 ft. lbs.).
  12. Fill differential with lubricant.

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Scheme 271: REMOVAL
Scheme 271: REMOVAL
  1. With vehicle in neutral, position vehicle on hoist.
  2. Remove vent hose.
  3. Remove differential cover (1) bolts (2).
  4. Remove cover and drain lubricant.

Scheme 272

Scheme 272: INSTALLATION
Scheme 272: INSTALLATION
  1. Apply a 4 mm (0.15 in.) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak.
  2. Install cover (2) and identification tag. Tighten cover bolts in a criss-cross pattern to 23 N.m (17 ft. lbs.).
  3. Fill differential to specifications.
  4. Install fill plug.

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Scheme 273: REMOVAL
Scheme 273: REMOVAL

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

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  1. Remove differential from housing.
  2. Remove bolts (1) holding ring gear (2) to differential case.
  3. Drive ring gear (2) from differential case with a soft hammer.
  4. Install bolts into two of the threaded holes in the companion flange 180° apart.
  5. Position Holder (special tool #6719A, Holder, Yoke) against the companion flange (1) and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so that the Holder (special tool #6719A, Holder, Yoke) is held to the flange. Remove the pinion nut.
  6. Remove the companion (10 flange with Remover (special tool #C-452, Puller, Companion Flange) (2).
  7. Remove pinion from differential housing.
  8. Remove pinion seal with a seal puller
  9. Remove front pinion bearing.
  10. Remove front pinion bearing cup with Remover (special tool #8831, Remover, Bearing Cup) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (3).
  11. Remove rear pinion bearing cup from housing (1) with Remover (special tool #8401, Remover, Bearing Cup) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (3).
  12. Remove collapsible spacer (1) from pinion.
  13. Remove rear pinion bearing from pinion shaft (1) with Puller/Press (special tool #C-293-PA, Puller, Press) (2) and Adapters (special tool #C-293-42, Block Set, Puller) (3).
  14. Remove depth shims (1) from pinion gear (2) shaft and record thickness of shims.

Scheme 280

Scheme 280: INSTALLATION
Scheme 280: INSTALLATION

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

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  1. Install rear pinion bearing cup with Installer (special tool #8692, Installer, Bearing Cup) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (3).
  2. Install front pinion bearing cup with Installer (special tool #8693, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
  3. Lubricate front pinion bearing and install bearing in the housing.
  4. Apply a light coating of gear lubricant on the lip of pinion seal.
  5. Install pinion seal with Installer (special tool #8695, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
  6. Place pinion depth shim (1) on the pinion shaft (2).
  7. Install rear pinion bearing (4) with Installer (special tool #6448A, Installer, Bearing/Gear) (2) and a press (1).
  8. Install new collapsible spacer (1) onto the pinion shaft.
  9. Lubricate rear pinion bearing and install the pinion gear in the housing.
  10. Install companion flange with Installer (special tool #C-3718, Installer, Flange) and Holder (special tool #6719A, Holder, Yoke) (2).
  11. Install new pinion nut and tighten to 271 N.m (200 ft. lbs.).
  12. Using Holder (special tool #6719A, Holder, Yoke) and a torque wrench set at 475 N.m (350 ft. lbs.). Tighten pinion nut until bearing end play is eliminated.
  13. Rotate pinion several times to seat pinion bearings.
  14. Tighten the pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to rotate is achieved. Measure torque to rotate frequently to avoid over crushing the collapsible spacer. Pinion Torque To Rotate is: Original Bearings: 1 - 2.5 N.m (10 - 20 in. lbs.) New Bearings: 2.0 - 2.8 N.m (18 - 25 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 result in damage.
  15. Invert start two ring gear bolts (1) to provide ring gear (2) bolt hole alignment.
  16. Install new ring gear bolts and alternately tighten to 108 N.m (80 ft. lbs.). CAUTION: Never reuse the ring gear bolts. Failure to follow these instruction will result in damage.
  17. Install differential in housing and verify gear mesh, backlash and contact pattern.

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Scheme 286: REMOVAL
Scheme 286: REMOVAL

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  1. Remove half shaft from disconnect side of the axle.
  2. Remove O-ring (1) and snap ring (2) from output shaft.
  3. Remove disconnect seal (1) bolts (2).
  4. Remove output shaft (1) and disconnect seal (2) with Remove (special tool #8420B, Remover, Shaft) (3) and Slide Hammer (special tool #C-3752, Slide Hammers).
  5. Remove disconnect seal (1) from output shaft (2).

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Scheme 290: DISASSEMBLY
Scheme 290: DISASSEMBLY

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  1. Remove output shaft bearing cup (1) from axle tube (2).
  2. Remove snap ring (1) from output shaft (2).
  3. Press output shaft (1) out of disconnect spline (2) and bearing (3).

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Scheme 293: ASSEMBLY
Scheme 293: ASSEMBLY

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Scheme 294
  1. Press output shaft bearing (1) on output shaft (2) with Installer (special tool #W-262, Installer, Bearing) (3).
  2. Press output shaft disconnect spline (1) on output shaft with Installer (special tool #W-262, Installer, Bearing) (2).
  3. Install disconnect spline (2) snap ring (1).
  4. Install output shaft bearing cup (1) in disconnect pocket (2).

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Scheme 295: INSTALLATION
Scheme 295: INSTALLATION

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  1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2).
  2. Install output shaft (1) in disconnect pocket (2).
  3. Install disconnect seal (1) on output shaft (2).
  4. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins (special tool #MD998412, Pins, Guide) (2).
  5. Install disconnect seal (1) in disconnect pocket with Installer (special tool #6761, Installer, Ball Joint) (2) and a hammer.
  6. Install disconnect seal (1) bolts (2) and tighten to 28 N.m (21 ft. lbs.).
  7. Install output shaft O-ring (1) and snap ring (2).
  8. Install half shaft.
  9. Verify differential fluid level and add fluid if necessary.

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Scheme 300
Scheme 300
  1. Remove half shaft from disconnect side of the axle.
  2. Remove O-ring (1) and snap ring (2) from the output shaft.
  3. Remove disconnect seal (1) bolts (2).
  4. Remove output shaft and disconnect seal (1) with Remover (special tool #8420B, Remover, Shaft) (2) and Slide Hammer (special tool #C-3752, Slide Hammers).

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Scheme 302
  1. Verify output shaft bearing cup (1) is seated in disconnect pocket (2).
  2. Install output shaft (1) in disconnect pocket (2).
  3. Apply Mopar® Thread Sealant with PTFE or Mopar® Axle RTV to the axle tube.
  4. Install disconnect seal (1) on output shaft (2).
  5. Align disconnect seal with bolt holes in disconnect pocket with a single Pin (special tool #MD998412, Pins, Guide) (1).
  6. Install disconnect seal in disconnect pocket with Installer (special tool #10117, Installer, Seal) (1) and a hammer.
  7. Apply Mopar® Thread Sealant with PTFE or Mopar® Axle RTV to the bolt threads.
  8. Install disconnect seal (1) bolts (2) and tighten to 28 N.m (21 ft. lbs.).
  9. Install output shaft O-ring (1) and snap ring (2).
  10. Install half shaft.
  11. Verify differential fluid level and add fluid if necessary.

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