Axle Shaft Assembly: Service and Repair
SHAFT-HALF (REAR)REMOVAL
NOTE: This procedure requires the compression of the rear suspension to ride height. A drive-on hoist should be used. If a drive-on hoist is not used, screw-style under-hoist jack stands are required to compress the rear suspension, facilitating rear halfshaft removal.
NOTE: Halfshaft inner and outer boots are not serviceable separately. Boot replacement requires entire shaft assembly replacement.
CAUTION: Unequal-length halfshafts are used. The left halfshaft is shorter than the right, and it is necessary to identify and tag halfshafts upon removal to ensure proper installation.
CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may cause the boot to pucker or crease, reducing the service life of the boot and joint. Avoid over angulating or stroking the C/V joints when handling the halfshaft.
1. With vehicle in neutral, position and raise vehicle on hoist.
2. Using 14 mm hex, remove axle drain plug (1) and drain rear axle fluid into container suitable for fluid reuse.
3. Install drain plug (1) and torque to:
^ 198 Axle: 60 Nm (44 ft. lbs.)
^ 210 Axle: 50 Nm (37 ft. lbs.)
4. Remove rear exhaust system (2) on V8-equipped models.
5. Remove wheel/tire assembly (1) from sides that shaft is to be removed.
6. Remove wheel hub nut (1) and discard.
7. Apply alignment index marks (3) to the propeller shaft rubber coupler (1) and axle flange (2).
8. Remove three (3) propeller shaft coupler-to-axle flange bolt/nuts.
9. Using suitable screwdriver (1), partially disengage halfshaft(s) (2) from axle assembly.
10. If a drive-on hoist is used, position transmission jack(l) to rear axle assembly. If a drive-on hoist is not used, compress rear suspension using screw-style under-hoist jack stands (2), then position transmission jack to rear axle assembly
11. Remove rear axle forward mount isolator (1) bolt/ nut (2).
CAUTION: Access to rear axle-to-crossmember bolts is best achieved by use of short socket and a flexible-head ratchet.
12. Remove two rear axle-to-crossmember bolts (1).
13. Carefully lower rear axle. While lowering axle, separate propeller shaft from axle and support with suitable rope or wire (1).
CAUTION: Unequal-length halfshafts are used. The left halfshaft is shorter than the right, and it is necessary to identify and tag halfshafts upon removal to ensure proper installation.
14. Lower axle just enough to remove halfshafts one at a time. Shift axle assembly in one direction, compressing one halfshaft while removing the other (1). Use caution to protect axle seal and journal.
CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may cause the boot to pucker or crease, reducing the service life of the boot and joint. Avoid over angulating or stroking the C/V joints when handling the halfshaft.
CAUTION: Use care while handling/storing halfshaft assembly. Damage to the slinger can result from improper handling. If slinger gets bent or damaged, straighten slinger to avoid contact with axle seal assembly.
15. Remove halfshaft from hub. Remove and inspect rubber isolation washer (1). Discard washer if rubber surfaces are worn away. Repeat on other side if necessary.
16. Remove axle seals (2) using suitable screwdriver.
INSTALLATION
NOTE: Halfshaft inner and outer boots are not serviceable separately. Boot replacement requires entire shaft assembly replacement.
CAUTION: Unequal-length halfshafts are used. The left halfshaft is shorter than the right, and it is necessary to identify and tag halfshafts upon removal to ensure proper installation.
CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may cause the boot to pucker or crease, reducing the service life of the boot and joint. Avoid over angulating or stroking the C/V joints when handling the halfshaft.
1. Install new axle seal(s) (1) using Tool 9223 (2).
2. Install halfshaft isolation washer (1). Washer is bi-directional, and can be installed in either direction.
3. Install halfshaft (2) to wheel hub/knuckle assembly. Install new hub nut (1) by hand.
NOTE: Inspect slinger(s) for handling damage. Straighten as necessary to avoid contact with axle seal.
NOTE: Use care when installing halfshaft to axle assembly. The halfshaft installation angle should be minimized to avoid damage to seal upon installation.
4. Lubricate halfshaft inner joint bearing journal (3) with Mopar Gear and Axle Lubricant (75W-140). Using new circlip(s), install halfshaft (1) to rear axle assembly. Use care not to damage axle seals (2). Verify proper installation by pulling outward on joint by hand.
5. Raise rear axle assembly into position. Align propeller shaft index marks (3) and start propeller shaft coupler-to-axle bolt/nuts by hand.
6. Install two rear axle-to-crossmember bolts (1) and torque to 220 Nm (162 ft. lbs.).
7. Install rear axle front mount isolator (1) as shown and torque bolt/nut to 65 Nm (48 ft. lbs.).
8. Again verify halfshaft inner joints are fully engaged to axle assembly
9. Remove transmission jack (1).
10. If used, remove screw-type under-hoist jack stands (2).
11. Torque propeller shaft coupler-to-axle flange bolt/ nuts to 58 Nm (43 ft. lbs.).
12. Using a 14mm hex, remove rear axle fill plug (1). Fill axle with Mopar 75W-140 Synthetic Gear & Axle Lubricant in the following quantities:
^ 198 Axle: 1.4 Liters (1.5 quarts)
^ 210 Axle: 1.6 Liters (1.7 quarts)
13. Install and torque fill plug (1) to:
^ 198 Axle: 60 Nm (44 ft. lbs.)
^ 210 Axle: 50 Nm (37 ft. lbs.)
14. V8 Models: Install exhaust system. Tighten band clamps (1) to 61 Nm (45 ft. lbs.).
15. Lower vehicle. Torque halfshaft hub nut (1) to 213 Nm (157 ft. lbs.). Install wheel center cap.
16. Install wheel/tire assembly (1) and torque lug nuts to 150 Nm (110 ft. lbs.).