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Dodge Durango
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Differential and Driveline » C205F axle » Diagnosis and testing
General information

Axle bearing problem conditions are usually caused by:

  • Insufficient or incorrect lubricant.
  • Foreign matter/water contamination.
  • Incorrect bearing preload torque adjustment.
  • Incorrect backlash

Axle gear problem conditions are usually the result of:

  • Insufficient lubrication.
  • Incorrect or contaminated lubricant.
  • Overloading (excessive engine torque) or exceeding vehicle weight capacity.
  • Incorrect clearance or backlash adjustment.

Axle component breakage is most often the result of:

  • Severe overloading.
  • Insufficient lubricant.
  • Incorrect lubricant.
  • Improperly tightened components.
  • Differential housing bores not square to each other.

DIAGNOSTIC CHART

Condition Possible Causes Correction
Wheel Noise 1. Wheel loose.

2. Faulty, brinelled wheel bearing.

1. Tighten loose nuts.

2. Replace bearing

Axle Shaft Noise 1. Misaligned axle tube.

2. Bent or sprung axle shaft.

3. End-play in pinion bearings.

4. Excessive gear backlash between the ring gear and pinion.

5. Improper adjustment of pinion gear bearings.

6. Loose pinion companion flange nut.

7. Scuffed gear tooth contact surfaces.

1. Inspect axle tube alignment.

Correct as necessary.

2. Inspect and correct as necessary

3. Refer to pinion pre-load information and correct as necessary.

4. Check adjustment of the ring gear and pinion backlash. Correct as necessary.

5. Adjust the pinion bearings pre-load.

6. Tighten the pinion companion flange nut.

7. Inspect and replace as necessary.

Axle Shaft Broke 1. Misaligned axle tube.

2 Vehicle overloaded.

3. Erratic clutch operation.

4. Grabbing clutch.

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

2. Replace broken shaft and avoid excessive weight on vehicle

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

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

Differential Cracked 1. Improper adjustment of the differential bearings.

2. Excessive ring gear backlash

3. Vehicle overloaded.

4. Erratic clutch operation.

1. Replace case and inspect gears and bearings for further damage.

Set differential bearing pre-load properly.

2. Replace case and inspect gears and bearings for further damage.

Set ring gear backlash properly.

3. Replace case and inspect gears and bearings for further damage.

Avoid excessive vehicle weight.

4. Replace case and inspect gears and bearings for further damage.

Avoid erratic use of clutch.

Differential Gears Scored 1. Insufficient lubrication.

2. Improper grade of lubricant.

3. Excessive spinning of one wheel/tire.

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

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

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

Loss Of Lubricant 1. Lubricant level too high.

2. Worn axle shaft seals.

3. Cracked differential housing.

4. Worn pinion seal.

5. Worn/scored companion flange.

6. Axle cover not properly sealed.

1. Drain lubricant to the correct level.

2. Replace seals.

3. Repair as necessary.

4. Replace seal

5. Replace companion flange and seal

6. Remove, clean, and re-seal cover.

Axle Overheating 1. Lubricant level low.

2. Improper grade of lubricant.

3. Bearing pre-loads too high.

4. Insufficient ring gear backlash.

1. Fill differential to correct level.

2. Fill differential with the correct fluid type and quantity

3. Re-adjust bearing pre-loads.

4. Re-adjust ring gear backlash

Gear Teeth Broke 1. Overloading.

2. Erratic clutch operation.

3. Ice-spotted pavement.

4. Improper adjustments.

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

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

3. Replace gears and examine remaining parts for damage.

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

Axle Noise 1. Insufficient lubricant.

2. Improper ring gear and pinion adjustment.

3. Unmatched ring gear and pinion.

4. Worn teeth on ring gear and/or pinion.

5. Loose pinion bearings.

6. Loose differential bearings.

7. Mis-aligned or sprung ring gear.

8. Loose differential bearing cap bolts.

9. Housing not machined properly

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

2. Check ring gear and pinion contact pattern.

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

4. Replace ring gear and pinion.

5. Adjust pinion bearing pre-load.

6. Adjust differential bearing pre-load.

7. Measure ring gear run-out.

Replace components as necessary

8. Inspect differential components and replace as necessary. Ensure that the bearing caps are torqued tot he proper specification.

9. Replace housing.

    More about «Diagnosis and testing»:

    General information

    Gear noise

    Bearing noise

    Vibration

    Driveline snap

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