300, Magnum, 2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
    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 jackstands 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.


    WARNING
    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.


    WARNING
    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 CV-joints when handling the halfshaft.

  2.  
  3. With vehicle in neutral, position and raise vehicle on hoist.
  4.  
  5. Using 14mm hex, remove axle drain plug and drain rear axle fluid into container suitable for fluid reuse.
  6.  
  7. Install drain plug and torque to:

    198 Axle: 44 ft. lbs. (60 Nm)
     
    210 Axle: 37 ft. lbs. (50 Nm)
     

  8.  
  9. Remove rear exhaust system on V8-equipped models.
  10.  
  11. Remove wheel/tire assembly from sides that shaft is to be removed.
  12.  
  13. Remove wheel hub nut and discard.
  14.  
  15. Apply alignment index marks to the driveshaft rubber coupler and axle flange.
  16.  
  17. Remove three driveshaft coupler-to-axle flange bolt/nuts.

    Click image to see an enlarged view

    Fig. Using suitable screwdriver (1), partially disengage halfshaft(s) (2) from rear axle assembly

  18.  
  19. Using suitable screwdriver, partially disengage halfshaft(s) from axle assembly.

    Click image to see an enlarged view

    Fig. If a drive-on hoist is used, position transmission jack (1) to rear axle assembly. If a drive-on hoist is not used, compress rear suspension using screw-style under-hoist jackstands (2), then position transmission jack to rear axle assembly

  20.  
  21. If a drive-on hoist is used, position transmission jack to rear axle assembly. If a drive-on hoist is not used, compress rear suspension using screw-style under-hoist jackstands, then position transmission jack to rear axle assembly.

    Click image to see an enlarged view

    Fig. Rear axle forward mount isolator (1) bolt/nut (2)

  22.  
  23. Remove rear axle forward mount isolator bolt/nut.
    WARNING
    Access to rear axle-to-crossmember bolts is best achieved by use of short socket and a flexible-head ratchet.



    Click image to see an enlarged view

    Fig. Rear axle-to-crossmember bolts (1)

  24.  
  25. Remove two rear axle-to-crossmember bolts.
  26.  
  27. Carefully lower rear axle. While lowering axle, separate driveshaft from axle and support with suitable rope or wire.
    WARNING
    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.

  28.  
  29. 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.
    WARNING
    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 CV-joints when handling the halfshaft.


    WARNING
    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.



    Click image to see an enlarged view

    Fig. Rubber isolation washer (1)

  30.  
  31. Remove halfshaft from hub. Remove and inspect rubber isolation washer. Discard washer if rubber surfaces are worn away. Repeat on other side if necessary.
  32.  
  33. Remove axle seals using suitable screwdriver.
  34.  

To install:


NOTE
Halfshaft inner and outer boots are not serviceable separately. Boot replacement requires entire shaft assembly replacement.


WARNING
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.


WARNING
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 CV-joints when handling the halfshaft.



Click image to see an enlarged view

Fig. Install new axle seal(s) (1) using Tool 9223 (2)

  1. Install new axle seal(s) using Tool 9223, or equivalent.
  2.  
  3. Install halfshaft isolation washer. Washer is bi-directional, and can be installed in either direction.
  4.  
  5. Install halfshaft to wheel hub/knuckle assembly. Install new hub nut 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.

  6.  
  7. Lubricate halfshaft inner joint bearing journal with Mopar® Gear and Axle Lubricant (75W-140). Using new circlip(s), install halfshaft to rear axle assembly. Use care not to damage axle seals. Verify proper installation by pulling outward on joint by hand.
  8.  
  9. Raise rear axle assembly into position. Align driveshaft index marks and start driveshaft coupler-to-axle bolt/nuts by hand.
  10.  
  11. Install two rear axle-to-crossmember bolts and torque to 162 ft. lbs. (220 Nm).
  12.  
  13. Install rear axle front mount isolator as shown and torque bolt/nut to 48 ft. lbs. (65 Nm).
  14.  
  15. Again verify halfshaft inner joints are fully engaged to axle assembly.
  16.  
  17. Remove transmission jack.
  18.  
  19. If used, remove screw-type under hoist jackstands.
  20.  
  21. Torque driveshaft coupler-to-axle flange bolt/nuts to 43 ft. lbs. (58 Nm).
  22.  
  23. Using a 14mm hex, remove rear axle fill plug. Fill axle with Mopar® 75W-140 Synthetic Gear & Axle Lubricant in the following quantities:

    198 Axle: 1.4L (1.5 qts.)
     
    210 Axle: 1.6L (1.7 qts.)
     

  24.  
  25. Install and torque fill plug to:

    198 Axle: 44 ft. lbs. (60 Nm)
     
    210 Axle: 37 ft. lbs. (50 Nm)
     

  26.  
  27. V8 Models: Install exhaust system. Tighten band clamps to 45 ft. lbs. (61 Nm).
  28.  
  29. Lower vehicle. Torque halfshaft hub nut to 157 ft. lbs. (213 Nm). Install wheel center cap.
  30.  
  31. Install wheel/tire assembly and torque lug nuts to 110 ft. lbs. (150 Nm).
  32.  

Front



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove wheel mounting nuts, then tire and wheel assembly.
  6.  
  7. While holding link ball joint stem from rotating, remove nut fastening stabilizer link to shock clevis bracket. Slide link ball joint stem from clevis bracket.
  8.  
  9. Remove nut and pinch bolt fastening clevis bracket to bottom of shock assembly.
  10.  
  11. Remove nut and bolt attaching shock clevis bracket to lower control arm.
  12.  
  13. Pull lower end of clevis bracket outward away from lower control arm bushing, then slide it off shock assembly. It may be necessary to use an appropriate prying tool to spread clamp area of clevis bracket allowing removal from shock assembly.
  14.  
  15. While a helper applies brakes to keep hub from rotating, remove hub nut from axle halfshaft.
    NOTE
    In some cases, it may be necessary to retract caliper piston in its bore a small amount in order to provide sufficient clearance between shoes and rotor to easily remove caliper from knuckle. This can usually be accomplished before mounting bolts are removed, by grasping rear of caliper and pulling outward working with guide pins, thus retracting piston. Never push on piston directly as it may get damaged.

  16.  
  17. Remove two bolts securing disc brake caliper and adapter to knuckle.
  18.  
  19. Remove disc brake caliper and adapter from knuckle as an assembly. Hang assembly out of way using wire or a bungee cord. Use care not to overextend brake hose when doing this.
  20.  
  21. Remove any clips retaining brake rotor to wheel studs.
  22.  
  23. Slide brake rotor off hub and bearing.
    WARNING
    In following step, use care not to damage ball joint seal boot while sliding the puller into place past seal boot.

  24.  
  25. Separate upper ball joint stud from knuckle.
  26.  
  27. Remove tool.
  28.  
  29. Remove nut from end of upper ball joint stud.
  30.  
  31. Remove clip fastening wheel speed sensor to knuckle.

    Click image to see an enlarged view

    Fig. Right front halfshaft removal/installation

  32.  
  33. Disengage right halfshaft from axle and remove from vehicle.
  34.  
  35. Remove left halfshaft from vehicle.
  36.  

To install:

  1. Install left halfshaft assembly.

    Click image to see an enlarged view

    Fig. Axle seal installation

  2.  
  3. Using Tool C-4193-A, install new axle seal.
  4.  
  5. Install right halfshaft assembly.
    NOTE
    Before installing halfshafts into hub/bearing assemblies, ensure isolation washer is present on end of halfshaft. Inspect washer making sure it is not worn or damaged. Washer is bi-directional and can be installed in either direction on shaft.



    Click image to see an enlarged view

    Fig. Halfshaft isolation washer

  6.  
  7. Install halfshaft isolation washer.
  8.  
  9. Install halfshaft into hub/bearing assembly.
  10.  
  11. Loosely install halfshaft hub nut, and do not tighten at this time.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  12.  
  13. Place upper ball joint stud through hole in top of knuckle and install nut. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 Nm + 90° turn (35 ft. lbs. + 90° turn) torque.
    NOTE
    Inspect brake shoes (pads) before installation.

  14.  
  15. Clean hub face to remove any dirt or corrosion where rotor mounts.
  16.  
  17. Install brake rotor over studs on hub and bearing.
  18.  
  19. Install disc brake caliper and adapter assembly over brake rotor.
  20.  
  21. Install mounting bolts securing caliper adapter to knuckle. Tighten bolts to 125 ft. lbs. (169 Nm) torque.
  22.  
  23. Pull lower end of shock assembly outward, then slide clevis bracket onto lower end. Slide clevis bracket onto shock assembly until bracket contacts collar on shock housing.
  24.  
  25. Install pinch bolt and nut fastening clevis bracket to bottom of shock assembly. Install pinch bolt from rear. Do not tighten at this time.
  26.  
  27. Slide clevis bracket over bushing mounted in lower control arm.
  28.  
  29. Install bolt and nut attaching shock clevis bracket to lower control arm. Do not tighten at this time.
  30.  
  31. Tighten pinch bolt attaching clevis bracket to shock assembly to 45 ft. lbs. (61 Nm) torque.
  32.  
  33. Slide stabilizer link ball joint stem into clevis bracket. Install nut fastening link to clevis bracket. Tighten nut by holding ball joint stud while turning nut. Tighten nut using crow foot wrench on torque wrench to 108 ft. lbs. (146 Nm) torque.
  34.  
  35. Attach wheel speed sensor cable routing clip at knuckle.
  36.  
  37. Install hub nut on end of axle halfshaft. While a helper applies brakes to keep hub from turning, tighten hub nut to 157 ft. lbs. (213 Nm) torque.
  38.  
  39. Install tire and wheel assembly. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm) torque.
  40.  
  41. Lower vehicle.
    NOTE
    When tightening lower shock clevis mounting bolt, do not attempt rotating bolt. Bolt shaft is serrated. Turn nut only.

  42.  
  43. Tighten lower shock clevis bracket bolt nut to 128 ft. lbs. (174 Nm) torque.
  44.  

 
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