Rear Axle - C235: Component Locations RAM Pickup 2500

SPECIAL TOOLS

10258 - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 10262.) 6310 - Remover, Bearing/Seal (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 6310-9 - Head (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 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.) 8541A - Set, Arbor Disc (Originally Shipped In Kit Number(s) 8555, 9975.) 8542 - Gauge, Pinion Height (Originally Shipped In Kit Number(s) 8555, 8700CC, 9975, 9976.) 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-293-37 - Block Set, Puller (Originally Shipped In Kit Number(s) 8418, 8562, C-293-M, DD-914-CLT-L.) C-293-47 - Block Set, Puller (Originally Shipped In Kit Number(s) 9975, C-293-M, DD-914-CLT-L.) C-293-PA - Puller, Press (Originally Shipped In Kit Number(s) 8418, 8837, C-293-M.) C-3095-A - Installer, Bearing C-3339A - Set, Dial Indicator (Originally Shipped In Kit Number(s) 9202.) C-3718 - Installer, Flange (Originally Shipped In Kit Number(s) 8418.) C-4076-B - Installer, Seal (Originally Shipped In Kit Number(s) 9975.) C-4164 - Wrench, Differential Preload (Originally Shipped In Kit Number(s) 9975.) C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) C-4198 - Installer, Axle Bearing (Originally Shipped In Kit Number(s) 8207.) C-4213 - Installer, Bearing (Originally Shipped In Kit Number(s) 9685, 9695, 9720-SUP, 9945-SUP2, 9995.) C-4309A - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 10262.) C-4310 - Installer, Bearing (Originally Shipped In Kit Number(s) C-4306.) C-452 - Puller, Companion Flange C-4735 - Handle, Driver (Originally Shipped In Kit Number(s) 9299.) 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.) D-129 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 6947, 6949, 8667.)

Scheme 355

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

1. Remove axle shaft. Refer to «SHAFT, Axle , Removal»(ref-457783-S29853725462012030200000) .
2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool.
3. Remove axle shaft bearing with (special tool #6310, Remover, Bearing/Seal) (2) (3) (4) (5) and (special tool #6310-9, Head) (7).

Scheme 362

1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube.
2. Install axle shaft bearing with (special tool #C-4198, Installer, Axle Bearing) and (special tool #C-4171, Driver Handle, Universal). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer.
3. Coat lip of the new axle seal with axle lubricant and install with (special tool #C-4076-B, Installer, Seal) and (special tool #C-4735, Handle, Driver).
4. Install the axle shaft (1). Refer to «SHAFT, Axle , Installation»(ref-457783-S02949234962012030200000) .
5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Refer to «COVER, Differential , Installation»(ref-457783-S25086658592012030200000) .

Scheme 363

1. Remove differential case from axle housing.
2. Remove differential bearings (3) from the case with (special tool #C-293-PA, Puller, Press) (1) and (special tool #C-293-47, Block Set, Puller) (2) and (special tool #C-293-3, Adapter, Bearing/Gear) (5).

Scheme 364

1. Install differential side bearings (3) with (special tool #C-4213, Installer, Bearing) (4) and (special tool #C-4171, Driver Handle, Universal) (1).
2. Install differential case into housing.

Scheme 365

Scheme 366

1. Remove fill and drain plugs from the differential housing.
2. Remove differential cover.
3. Clean housing cavity with brake cleaner and a lint free cloth. NOTE: Do not use steam, kerosene or gasoline to clean the housing.
4. Remove axle shafts. Refer to «SHAFT, Axle , Removal»(ref-457783-S29853725462012030200000) . NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
5. Mark differential housing and bearing caps (3) for installation reference.
6. Remove bearing threaded adjuster lock from each bearing cap.
7. Loosen differential bearing cap bolts.
8. Loosen differential bearing adjusters through the axle tubes (1) with (special tool #C-4164, Wrench, Differential Preload) (3).
9. Hold differential case while removing bearing caps. NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.
10. Remove differential case.

Scheme 367

Scheme 368

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

Scheme 369

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

Scheme 370

Scheme 371

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

Scheme 372

Scheme 373

1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups.
2. Install differential assembly into the housing.
3. Install differential bearing caps (4) in their original locations.
4. Install bearing cap bolts and tighten the upper bolts to 14 N.m (10 ft. lbs.). Tighten lower bolts finger-tight until the bolt head is seated. Then perform the differential bearing preload and adjustment procedure. Refer to «Adjustments»(ref-457783-S33396566482012030200000) . NOTE: Be sure that all bearing cap bolts are tightened to their final torque of 136 N.m (100 ft. lbs.) before proceeding.
5. Install axle shafts. Refer to «SHAFT, Axle , Installation»(ref-457783-S02949234962012030200000) .
6. Apply a 6.35mm (1/4 in.) bead of orange Mopar® Axle RTV Sealant (1) or equivalent to the cover (2) with the bead to the inner side of the bolt holes. 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 result in a leak.
7. Install cover and tighten cover bolts to 44 N.m (32 ft. lbs.).
8. Fill differential with lubricant to specifications. Refer to «Capacities and Recommended Fluids , Specifications»(ref-457775-S18332386902012030200000) .

Note. Limited Slip Differential (LSD) equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.