Chrysler Full-Size Trucks 1967-1988 Repair Guide

Axle Shaft, Bearing and Seal

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REMOVAL & INSTALLATION



Early Dana 44 Without Locking Hubs

See Figures 1 and 2

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the grease cap.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Axle and steering knuckle-W100/200

  1. Remove the drive flange bolts and snapring.
  2.  
  3. Using a puller, remove the drive flange.
  4.  
  5. Unbend the locktab and remove the outer locknut.
  6.  
  7. Remove the lockring and the bearing inner adjusting nut.
  8.  



Click image to see an enlarged view

Fig. Fig. 2: Wheel bearing adjusting nut, retainer washer and locknut

  1. Remove the hub and drum assembly. Take care not to drop the outer bearing.
  2.  
  3. Remove the brake backing plate bolts and wire the plate up out of the way. DO NOT DISCONNECT THE BRAKE LINE.
  4.  
  5. Using a soft mallet, tap the spindle from the knuckle.
  6.  
  7. Pull the axle shaft from the housing. The axle shaft U-joint may be rebuilt in the same manner as a driveshaft U-joint, explained earlier in this information.
  8.  
  9. Inspect the spindle bushing for wear and/or damage. Replace it if it looks bad.
  10.  

To install:
  1. Replace all seals.
  2.  
  3. Drive a new spindle bushing into place.
  4.  
  5. Lubricate the bushing and axle splines.
  6.  
  7. Carefully install the axle shaft into the housing, engaging the spline with the differential. Take care to avoid seal damage.
  8.  
  9. Install the spindle.
  10.  
  11. Install the backing plate. Torque the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Carefully position the hub and drum assembly on the spindle.
  14.  
  15. Install the outer bearing cone and roller, and along with the adjusting nut.
  16.  

The adjusting nut has a small dowel on one side. This dowel faces outward to engage the locking ring.

  1. Using a hub nut wrench tighten the bearing adjusting nut to 50 ft. lbs. (68 Nm), while rotating the wheel back and forth to seat the bearings.
  2.  
  3. Back off the adjusting nut approximately 90°.
  4.  
  5. Install the lockring by turning the nut to the nearest hole and inserting the dowel pin.
  6.  

The dowel pin must seat in a lockring hole for proper bearing adjustment and wheel retention.

  1. Install the outer locknut and tighten to 50-80 ft. lbs. (68-108 Nm). Final end-play of the wheel on the spindle should be 0.001-0.010 in. (0.025-0.250mm). Bend the locking tab over the nut.
  2.  
  3. Install the drive flange bolts and snapring.
  4.  
  5. Install the grease cap.
  6.  
  7. Remove the safety stands and lower the vehicle.
  8.  

Dana 44 Models Through 1984 with Manual or Automatic Locking Hubs

  1. Raise the vehicle and install safety stands.
  2.  
  3. Refer to Manual or Automatic Free Running Hub removal and installation and remove the hub assemblies.
  4.  
  5. Remove the wheel bearing locknut, using a hub nut wrench.
  6.  
  7. Remove the lockring from the bearing adjusting nut. This can be done with your finger tips or a screwdriver.
  8.  
  9. Using a hub nut wrench remove the bearing adjusting nut.
  10.  
  11. Remove the caliper and suspend it out of the way. Please refer to Brakes of this guide.
  12.  
  13. Slide the hub and disc assembly off of the spindle. The outer wheel bearing will slide out as the hub is removed, so be prepared to catch it.
  14.  

To install:
  1. Carefully position the hub and disc assembly on the spindle.
  2.  
  3. Install the outer bearing cone and roller, along with the adjusting nut.
  4.  

The adjusting nut has a small dowel on one side. This dowel faces outward to engage the locking ring.

  1. Using a hub nut wrench tighten the bearing adjusting nut to 50 ft. lbs. (68 Nm), while rotating the wheel back and forth to seat the bearings.
  2.  
  3. Back off the adjusting nut approximately 90°.
  4.  
  5. Install the lockring by turning the nut to the nearest hole and inserting the dowel pin.
  6.  

The dowel pin must seat in a lockring hole for proper bearing adjustment and wheel retention.

  1. Install the outer locknut and tighten to 50-80 ft. lbs. (68-108 Nm). Final end-play of the wheel on the spindle should be 0.001-0.010 in. (0.025-0.250mm).
  2.  
  3. Assemble the hub parts.
  4.  
  5. Install the caliper.
  6.  
  7. Remove the safety stands and lower the vehicle.
  8.  

1985-88 Dana 44 Models
LEFT SIDE AXLE SHAFT

See Figures 3 and 4

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the caliper and support it up and out of the way. DO NOT DISCONNECT THE BRAKE LINE.
  6.  
  7. Remove the inboard brake pad.
  8.  
  9. Remove the hub/rotor assembly.
  10.  
  11. Unbolt, then remove the splash shield and spindle from the knuckle. It may be necessary to tap the spindle loose with a soft mallet.
  12.  
  13. Disconnect the vacuum lines and wire at the disconnect housing on the axle.
  14.  
  15. Remove the disconnect housing cover, gasket and shield.
  16.  
  17. Carefully pull the intermediate shaft through the seal and out of the axle housing.
  18.  
  19. Remove the shift collar from the disconnect housing.
  20.  
  21. Drive out the inner axle shaft seal and remove it from the disconnect housing. Discard the seal.
  22.  

Some axles may have a seal guard. Replacement seal do not use a guard.

  1. Remove the needle bearing from the intermediate shaft using tool D-330 or equivalent.
  2.  
  3. Remove the differential cover. Allow the oil to drain into a drain pan.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Special tools to disconnect the axle housing



Click image to see an enlarged view

Fig. Fig. 4: Removing the bearing from the intermediate shaft

  1. While pushing inward on the inner shaft, remove the C-lock from the groove on the shaft.
  2.  
  3. Remove the inner shaft with tools D-354-4 and adapter D-354-3.
  4.  
  5. Remove the bearing from the inner shaft with tools D-354-4, D-354-1 and C-637, or equivalents.
  6.  
  7. Thoroughly clean and inspect all parts. Replace any worn or damaged parts.
  8.  

To install:
  1. Using tools D-354-4, D-354-2 and C-637, install a new bearing on the inner shaft.
  2.  
  3. Position the inner shaft in the axle housing using tools D-354-4 and adapter D-354-3.
  4.  
  5. Carefully slide the shaft into position and install the C-lock.
  6.  
  7. Place a new axle shaft seal on tool 5041-1 and position the assembly in the disconnect housing. Screw threaded bar 5041-2 through the seal and into tool 5041-1. Place tool 5041-3 and the nut on the end of the bar and tighten the nut until the tool reaches the shoulder of the bar.
  8.  
  9. Install the shift collar onto the splined end of the inner shaft.
  10.  
  11. Using tool D-328 and handle C-4171, install the needle bearing into the intermediate shaft.
  12.  
  13. Coat the splined end of the intermediate shaft with multi-purpose chassis lube and install it through the inner axle seal. Avoid damage to the seal.
  14.  
  15. Install the disconnect housing cover and gasket. Make sure that the shift fork indexes the groove in the shift collar.
  16.  
  17. Torque the cover bolts to 10 ft. lbs. (13 Nm).
  18.  
  19. Connect the vacuum lines and wire. Install the clip securely around the 4-wheel drive indicator switch connector.
  20.  
  21. Install the splash shield and spindle. Use new nuts tightened to 30 ft. lbs. (40 Nm)
  22.  
  23. Install the hub and bearings.
  24.  
  25. Install the spacer, drive gear and snapring.
  26.  
  27. Apply RTV sealant on the mating edge of the cap and install it.
  28.  
  29. Install the inboard brake pad and caliper. See Brakes .
  30.  
  31. Thoroughly clean the carrier cover mating surfaces and install the cover using a bead of RTV sealant in place of a gasket. Torque the cover bolts to 40 ft. lbs. (54 Nm).
  32.  
  33. Fill the axle with fluid.
  34.  
  35. Install the wheel.
  36.  

RIGHT SIDE AXLE SHAFT

See Figure 5

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheel.
  4.  
  5. Remove the caliper and support it up and out of the way. DO NOT DISCONNECT THE BRAKE LINE.
  6.  
  7. Remove the inboard brake pad.
  8.  
  9. Remove the hub/rotor assembly.
  10.  
  11. Unbolt, then remove the splash shield and spindle from the knuckle. It may be necessary to tap the spindle loose with a soft mallet.
  12.  
  13. Remove the caliper adapter from the knuckle.
  14.  
  15. Carefully pull the axle shaft from the housing.
  16.  

To install:
  1. Thoroughly clean and inspect all parts. Replace any worn or damaged parts. The axle U-joint can be rebuilt in the same manner as a driveshaft U-joint, explained above.
  2.  
  3. Install a new seal on the axle shaft stone shield with the lip facing the shaft splines.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Lubricating the lip seal

  1. Carefully slide the shaft into the housing, avoiding damage to the seal at the side gears.
  2.  
  3. Install the spindle and splash shield. Tighten the nuts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install the hub/rotor assembly.
  6.  
  7. Install the spacer, drive gear and snapring.
  8.  
  9. Apply RTV sealant on the mating edge of the grease cap and install the cap.
  10.  
  11. Install the caliper adapter and torque the bolts to 85 ft. lbs. (115 Nm).
  12.  
  13. Install the inboard pad and caliper. Please refer to Brakes .
  14.  
  15. Install the wheels, lower the vehicle then, tighten the nuts to specification, refer to Suspension & Steering .
  16.  

Models With Full-Time 4-Wheel Drive
  1. Remove the wheel cover.
  2.  
  3. Remove the cotter pin and loosen the axle shaft nut.
  4.  
  5. Raise and support the front end on jackstands.
  6.  
  7. Remove the wheels.
  8.  
  9. Unbolt the caliper and support it out of the way. DO NOT DISCONNECT THE BRAKE LINE.
  10.  
  11. Remove the inboard brake pad.
  12.  
  13. Remove the axle shaft nut and washer.
  14.  
  15. Through the hole provided in the rotor, remove the 6 retainer bolts.
  16.  
  17. Position puller C-4358, or equivalent, over the wheel lugs and install the lug nuts. Tighten the main screw of the puller to remove the hub, bearings, retainer and outer seal as an assembly.
  18.  
  19. Remove the puller.
  20.  
  21. Remove the caliper adapter from the knuckle.
  22.  
  23. Place a prybar behind the inner axle shaft yoke and push the bearings out of the knuckle.
  24.  
  25. Some knuckles have an O-ring. If so, remove and discard it.
  26.  
  27. Carefully pull the axle shaft from the axle. Remove the seal and slinger from the shaft.
  28.  
  29. The U-joint can now be disassembled in the same manner as a driveshaft U-joint, explained earlier in this information.
  30.  

To install:
  1. If you removed the brake dust shield, install it now. Torque the mounting bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Apply RTV silicone sealer to the sealing surfaces of the axle shaft.
  4.  
  5. Using a driver, install the slinger onto the shaft.
  6.  
  7. Install a new seal on the slinger with the lip towards the splines.
  8.  
  9. Carefully insert the shaft into the axle housing, being careful to avoid damage to the differential side gear seal.
  10.  
  11. Insert a prybar though the U-joint and wedge the shaft inward as far as it will go. Make sure that it is wedged securely and can't be moved.
  12.  
  13. Using adapter tool C-4398-2 and driver, install the seal cup in the knuckle until it is bottomed. A small amount of wheel bearing grease on the adapter will help hold the cup in position. Leave the tool in position for the time being.
  14.  
  15. Apply a 1 / 4 in. (6.3mm) bead of RTV sealant to the retainer face on the chamfer.
  16.  
  17. Carefully remove the seal installing tool so that the outer shaft remains centered.
  18.  

If the shaft is touched, make sure that the seal lip is still riding inside the cup.

  1. Position the bearing retainer on the knuckle so that the lube fitting is facing directly forward. This is extremely important.
  2.  
  3. Install the hub, rotor and bearing assembly, then torque the retainer bolts to 30 ft. lbs. (40 Nm) in a crisscross pattern.
  4.  
  5. Install the brake adapter. Torque the bolts to 85 ft. lbs. (115 Nm).
  6.  
  7. Remove the prybar from the U-joint.
  8.  
  9. Install the axle shaft nut and tighten it to 100 ft. lbs. (135 Nm), then continue tightening it to align the cotter pin holes. Install the cotter pin.
  10.  
  11. Using the lube fitting, fill the knuckle with multi-purpose EP grease until the grease is seen flowing through the inner seal.
  12.  
  13. Remove the grease gun and rotate the hub several times.
  14.  
  15. Install the grease gun and continue filling the knuckle until grease appears around at least 50% of the seal circumference.
  16.  
  17. Install the inner brake pad and caliper. Please refer to Brakes .
  18.  
  19. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  20.  

Dana 60
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the caliper from the knuckle and wire it out of the way.
  4.  
  5. Remove the locking hub.
  6.  
  7. Remove the front wheel bearing. See General Information & Maintenance .
  8.  
  9. Remove the hub and rotor assembly.
  10.  
  11. Remove the spindle-to-knuckle bolts. Tap the spindle from the knuckle using a plastic mallet.
  12.  
  13. Remove the splash shield and caliper support.
  14.  
  15. Pull the axle shaft out through the knuckle.
  16.  
  17. Using a slide-hammer and bearing cup puller, remove the needle bearing from the spindle.
  18.  
  19. Clean the spindle bore thoroughly and make sure that it is free of nicks and burrs. If the bore is excessively pitted or scored, the spindle must be replaced.
  20.  

To install:
  1. Insert a new spindle bearing in its bore with the printing facing outward. Drive it into place with a driver. Install a new bearing seal with the lip facing away from the bearing.
  2.  
  3. Pack the bearing with waterproof wheel bearing grease.
  4.  
  5. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with waterproof wheel bearing grease.
  6.  
  7. Carefully guide the axle shaft through the knuckle and into the housing. Align the splines and fully seat the shaft.
  8.  
  9. Place the bronze spacer on the shaft. The chamfered side of the spacer must be inboard.
  10.  
  11. Install the splash shield and caliper support.
  12.  
  13. Place the spindle on the knuckle and install the bolts. Torque the bolts to 50-60 ft. lbs. (67-81 Nm).
  14.  
  15. Install the hub/rotor assembly on the spindle.
  16.  
  17. Reinstall the caliper assembly on the knuckle.
  18.  
  19. Assemble the wheel bearings.
  20.  
  21. Assemble the locking hub.
  22.  
  23. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  24.  

Dana 70 Dana F-375
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake drums. See Brakes .
  6.  
  7. Matchmark the drive flange and the hub.
  8.  
  9. Remove the nuts and lockwashers, then install puller screws using the 2 threaded holes in the flange.
  10.  
  11. Pull the flange from the hub.
  12.  
  13. Remove the hub and bearings.
  14.  
  15. Remove the attaching bolts and pull the brake supports from the knuckle. Wire them up and out of the way.
  16.  
  17. Using a soft mallet, tap the spindle from the knuckle.
  18.  
  19. Pull the short outer shaft and female section of the universal drive assembly from the axle housing.
  20.  
  21. Pull the male section and long inner shaft from the housing.
  22.  
  23. Discard all seals and seal bushings.
  24.  

To install:
  1. Thoroughly clean and inspect all parts.
  2.  
  3. Drive a new seal and bushing into the end of the housing. The seal lip should face inwards.
  4.  
  5. Pack the axle shaft U-joints with chassis lubricant. Install both the inner and outer axle shafts. Note that the shaft have numerical mating marks. Identical numbers should be mated during assembly.
  6.  

On some axles the mating numbers are not identical. That's okay as long as the axle operates satisfactorily.

  1. Position the spindle and brake supports on the knuckle. Install the bolts and lockwashers.
  2.  
  3. Pack the wheel bearings and coat the inside of the hubs with wheel bearing grease.
  4.  
  5. Adjust the wheel bearings by turning the inner adjusting nut tightly, then backing it off 1 / 6 turn.
  6.  
  7. Install the lockring making sure that the pin on the inner nut enters one of the holes in the lockring. It's okay to move the inner nut slightly to position the pin.
  8.  
  9. Install the outer nut and torque it to 50 ft. lbs. (68 Nm).
  10.  
  11. Install the drive flange, using a new gasket.
  12.  
  13. Coat the flange and drum contact surfaces with anti-seize compound and install the drum.
  14.  
  15. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  16.  

 
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