Dodge Durango

 Service Manual

Differential and Driveline » 8 1/4 And 9 1/4 axle » Removal and installation
Pinion seal

REMOVAL

(1) Raise and support the vehicle.

(2) Scribe a mark on the universal joint, companion flange, and pinion shaft for installation reference.

(3) Disconnect the propeller shaft from the companion flange. Secure the propeller shaft in an upright position to prevent damage to the rear universal joint.

(4) Remove the wheel and tire assemblies.

(5) Remove the brake drums to prevent any drag.

The drag may cause a false bearing preload torque measurement.

(6) Rotate the companion flange three or four times.

(7) Measure the amount of torque necessary to rotate the pinion with a (in. lbs.) dial-type torque wrench. Record the torque reading for installation reference.

(8) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(9) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

(10) Hold the flange with Holder 6719. Remove the pinion nut and washer.

(11) Remove the companion flange with Remover C-452 (Fig. 15).

(12) Remove the pinion seal with suitable pry tool or slide-hammer mounted screw.

Fig. 15 Companion Flange Removal

1 - COMPANION FLANGE

2 - PULLER TOOL

INSTALLATION

(1) Clean the seal contact surface in the housing bore.

(2) Examine the splines on the pinion shaft for burrs or wear. Remove any burrs and clean the shaft.

(3) Inspect companion flange for cracks, worn splines and worn seal contact surface. Replace companion flange if necessary.

NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required.

(4) Apply a light coating of gear lubricant on the lip of pinion seal.

(5) Install the new pinion seal with Installer C-4076-B and Handle C-4735-1 for 8 1/4 axles (Fig.

16) and Installer C-3860-A and Handle C-4171 for 9 1/4 axles.

NOTE: The seal is correctly installed when the seal flange contacts the face of the differential housing.

(6) Position the companion flange on the end of the shaft with the reference marks aligned.

(7) Install socket head bolts into two of the threaded holes in the companion flange, 180 apart.

(8) Position Holder 6719 against the companion flange and install a hex head bolt and washer into one of the remaining threaded holes. Tighten the bolt and washer so that the Holder 6719 is held to the flange.

Fig. 16 8 1/4 Axle Pinion Seal Installation

1 - SPECIAL TOOL C-4735

2 - DIFFERENTIAL HOUSING

3 - SPECIAL TOOL C-4076-A

(9) Seat companion flange on pinion shaft with Installer C-3718 and Holder 6719.

(10) Remove the Installer C-3718 and install the pinion washer and a new pinion nut. The convex side of the washer must face outward.

CAUTION: Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Damage to collapsible spacer or bearings may result.

(11) Hold companion flange with Holder 6719 and tighten the pinion nut to 285 N*m (210 ft. lbs.) (Fig.

17). Rotate pinion several revolutions to ensure the bearing rollers are seated.

(12) Rotate the pinion using an (in. lbs.) torque wrench. Rotating torque should be equal to the reading recorded during removal, plus an additional 0.56 N*m (5 in. lbs.) (Fig. 18).

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. The torque sequence will then have to be repeated.

(13) If the rotating torque is low, use Holder 6719 to hold the companion flange (Fig. 17) and tighten the 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.

Fig. 17 Tightening Pinion Nut

1 - DIFFERENTIAL HOUSING

2 - COMPANION FLANGE HOLDER

3 - TORQUE WRENCH

Fig. 18 Check Pinion Rotation Torque

1 - COMPANION FLANGE

2 - INCH POUND TORQUE WRENCH

(14) The seal replacement is unacceptable if the final pinion nut torque is less than 285 N*m (210 ft.

lbs.).

(15) Install the propeller shaft with the installation reference marks aligned.

(16) Tighten the companion flange bolts to 108 N*m (80 ft. lbs.).

(17) Install the brake drums.

(18) Install wheel and tire assemblies and lower the vehicle.

(19) Check the differential housing lubricant level.

Rear axle

Axle shaft

8 1/4 And 9 1/4 axle seal and bearing

Pinion seal

Differential

Differential side bearings

Ring gear and exciter ring

Pinion gear

Final assembly