Chrysler Full-Size Trucks 1967-1988 Repair Guide

Axle Shaft, Bearing and Seal

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Before servicing any axle shafts, be sure to jack and support the truck so that both rear wheels are off the ground. This will ensure that the vehicle will not roll off the supports if the vehicle is equipped with a limited slip rear axle and one wheel is turned inadvertently.

REMOVAL & INSTALLATION



Chrysler 8 3 / 4 in. Axle

Whenever this axle assembly is serviced, both the brake support plate gaskets and the inner axle shaft oil seal must be renewed.

  1. Jack up the rear of the truck and remove the rear wheels.
  2.  
  3. Detach the clips which secure the brake drum to the axle shaft studs and remove the brake drum.
  4.  
  5. Remove the axle shaft retaining nuts through the access hole in the axle shaft flange. The right-side axle shaft has a threaded adjuster in the retainer plate and a lock under one of its studs which should be removed at this time.
  6.  
  7. Remove the parking brake strut.
  8.  
  9. Attach a suitable puller to the axle shaft flange and remove the axle shaft.
  10.  
  11. Remove the brake assembly from the axle housing.
  12.  
  13. Remove the axle shaft oil seal from the axle housing.
  14.  


WARNING
It is advisable to position some sort of protective sleeve over the axle shaft seal surface next to the bearing collar to protect the seal surface. Never use a torch or other heat source as an aid in removing any axle shaft components as this will result in serious damage to the axle assembly.

To install:
  1. Wipe the axle housing seal bore clean. Install a new axle shaft oil seal.
  2.  
  3. Clean the axle shaft bearing cavity.
  4.  
  5. Grease and install the axle shaft bearing in the cavity. Be sure that the bearing is not cocked and that it is seated firmly against the shoulder.
  6.  
  7. Install the axle shaft bearing seal. It should be seated beyond the end of the flange face.
  8.  
  9. Insert the axle shaft, making sure that the splines do not damage the seal. Be sure that the splines are properly engaged with the differential side gear splines.
  10.  
  11. Install the C-locks in the grooves on the axle shafts. Pull the shafts outward so that the C-locks seat in the counterbore of the differential side gears.
  12.  
  13. Install the differential pinion shaft through the case and pinions. Install the lockscrew and secure it in position.
  14.  
  15. Clean the housing and gasket surfaces. Install the cover and a new gasket.
  16.  
  17. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  18.  
  19. Refill the axle with the specified lubricant.
  20.  

Replacement differential cover gaskets may not be available. The use of gel type, nonsticking sealant is recommended.

Chrysler 83/8in., 91/4in. and 91/4Heavy Duty Axles

See Figures 1 through 15

There is no provision for axle shaft end-play adjustment on these axles.



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Fig. Fig. 1: 83/8 inch rear axle



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Fig. Fig. 2: 91/4 inch rear axle

  1. Jack up the vehicle and remove the rear wheels.
  2.  
  3. Clean all dirt from the housing cover. Obtain a drain pan and place under rear axle.
  4.  



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Fig. Fig. 3: Clean the outside of the cover before working



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Fig. Fig. 4: Inspect the fill plug for deterioration

  1. Remove the fill plug and check to see if you need to replace it due to deterioration.
  2.  
  3. Loosen the few bottom bolts to drain some of the gear oil. Proceed by removing the housing cover completely.
  4.  



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Fig. Fig. 5: Loosen the few lower bolts...



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Fig. Fig. 6: ... drain fluid, but make sure you have a pan ready



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Fig. Fig. 7: Now that you have drained completely, you can remove the cover

  1. Remove the brake drum.
  2.  



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Fig. Fig. 8: With the cover removed, the pinion and C-locks are now accessible

  1. Rotate the differential case until the differential pinion shaft lockscrew can be removed. Remove the lockscrew and pinion shaft.
  2.  



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Fig. Fig. 9: You can use your fingers to remove the lockscrew



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Fig. Fig. 10: Loosening or tightening the pinion shaft lockscrew

  1. Push the axle shafts toward the center of the vehicle and remove the C-locks from the grooves on the axle shafts.
  2.  



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Fig. Fig. 11: Removal and installation of the axle shaft C-locks

  1. Pull the axle shafts from the housing, being careful not to damage the bearing which remains in the housing.
  2.  
  3. Inspect the axle shaft bearings and replace any doubtful parts. Whenever the axle shaft is replaced, the bearings should also be replaced.
  4.  



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Fig. Fig. 12: 91/4 inch HD removal of the axle bearing and seal

  1. Remove the axle shaft seal from the bore in the housing, using the button end of the axle shaft.
  2.  
  3. Remove the axle shaft bearing from the housing. On the 8 3 / 8 in. and 9 1 / 4 in. axle, use a slide hammer and adapter. On the 9 1 / 4 in. HD axle, use a puller such as C-4828. Do not reuse the bearing or the seal.
  4.  



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Fig. Fig. 13: Removing the axle bearing and seal

  1. Check the bearing shoulder in the axle housing for imperfections. These should be corrected with a file.
  2.  
  3. Clean the axle shaft bearing cavity.
  4.  

To install:
  1. Grease and install the axle shaft bearing in the cavity. An installer tool is recommended, although a driver can be used. Be sure that the bearing is not cocked and that it is seated firmly against the shoulder.
  2.  



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Fig. Fig. 14: Use a special tool to install the axle shaft seal

  1. Install the axle shaft bearing seal. It should be seated beyond the end of the flange face.
  2.  
  3. Insert the axle shaft, making sure that the splines do not damage the seal. Be sure that the splines are properly engaged with the differential side gear splines.
  4.  
  5. Install the C-locks in the grooves on the axle shafts. Pull the shafts outward so that the C-locks seat in the counterbore of the differential side gears.
  6.  
  7. Install the differential pinion shaft through the case and pinions. Install the lockscrew and secure it in position.
  8.  
  9. Clean the housing and gasket surfaces. Install the cover and a new gasket.
  10.  
  11. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  12.  
  13. Refill the axle with the specified lubricant.
  14.  

Replacement differential cover gaskets may not be available. The use of gel type nonsticking sealant is recommended.



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Fig. Fig. 15: Common rear cover to apply sealant too

Chrysler 95/8in. Axle

  1. Jack up the vehicle and remove the rear wheels.
  2.  
  3. Remove the drum from the axle shaft.
  4.  
  5. Remove the axle shaft flange nuts.
  6.  
  7. Install puller screws in the threaded holes provided and tighten the screws to loosen the shaft.
  8.  

If threaded holes are not provided, rap the flange sharply with a soft mallet to loosen the shaft.

  1. Pull the shaft from the housing.
  2.  

To install:
  1. Install the shaft into the housing.
  2.  
  3. Always use a new gasket coated with sealer.
  4.  
  5. Tighten the flange nuts to 30-35 ft. lbs. (40-47 Nm).
  6.  
  7. Install the brake drum.
  8.  
  9. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  10.  

Dana (Spicer) 60 and 70
1967-84 MODELS

See Figures 16 and 17

  1. Jack up the vehicle and remove the rear wheels.
  2.  
  3. Remove the drum from the axle shaft.
  4.  
  5. Remove the axle shaft flange nuts and washers.
  6.  
  7. Rap the axle shafts sharply in the center of the flange with a hammer to free the dowels.
  8.  

To install:
  1. Remove the tapered dowels and axle shafts. Some models are equipped with bolts rather than dowels.
  2.  



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Fig. Fig. 16: Exploded view of the Dana 70 rear axle assembly

  1. Clean the gasket area with solvent and install a new flange gasket.
  2.  

To install:
  1. Install the axle shaft into the housing.
  2.  
  3. If the axle has an outer wheel bearing seal, install new gaskets on each side of the seal mounting flange.
  4.  



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Fig. Fig. 17: Exploded view of the Dana 60 and 60M axle assembly

  1. Install the tapered dowels, lockwashers, and nuts. Tighten the nuts to 40-70 ft.lbs. (54-94 Nm) with 7 / 16 in. (11mm) studs and 65-105 ft.lbs. (88-142 Nm) with 1 / 2 in. (12mm). Some axles have bolts instead of studs and tapered dowels. Bolt torque is 45-75 ft.lbs. (61-101 Nm).
  2.  
  3. Install the brake drum.
  4.  
  5. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  6.  

1985-88 MODELS
  1. Jack up the vehicle and remove the rear wheels.
  2.  
  3. Remove the drum from the axle shaft.
  4.  
  5. Remove the axle shaft flange locknuts and washers, or bolts.
  6.  
  7. On axles with locknuts, rap the axle shafts sharply in the center of the flange with a hammer to free the dowels.
  8.  
  9. Remove the tapered dowels and/or axle shafts.
  10.  

To install:
  1. Clean the gasket area with solvent and install a new flange gasket.
  2.  
  3. Install the axle shaft into the housing.
  4.  
  5. If the axle has an outer wheel bearing seal, install new gaskets on each side of the seal mounting flange.
  6.  
  7. Install the tapered dowels, lockwashers, and nuts or Durlock® bolts. Tighten the 7 / 16 -20 nuts to 40-70 ft. lbs. (54-94 Nm); the 1 / 2 -20 nuts to 65-105 ft. lbs. (88-142 Nm) the Durlock® bolts to 60 ft. lbs. (81 Nm).
  8.  
  9. Install the brake drum.
  10.  
  11. Install the wheels, lower the vehicle, then tighten the lug nuts to specification in Suspension & Steering .
  12.  

Full-Floating Dana 60 and 70 Axles

See Figures 18 and 19

The wheel bearings on the 200 and 300 series full floating rear axles are packed with wheel bearing grease. Axle lubricant can also flow into the wheel hubs and bearings, however, wheel bearing grease is the primary lubricant.

1967-84 MODELS
  1. Set the parking brake and loosen the axle shaft bolts.
  2.  
  3. Raise the rear wheels off the floor and place jackstands under the rear axle housing so that the axle is parallel with the floor.
  4.  
  5. Remove the axle shaft bolts.
  6.  
  7. Remove the axle shaft and gaskets.
  8.  
  9. With the axle shaft out, remove the gasket from the axle shaft flange studs.
  10.  
  11. Bend the lockwasher tab away from the locknut, and then remove the locknut, lockwasher, and the adjusting nut.
  12.  
  13. Remove the outer bearing cone and pull the wheel straight off the axle.
  14.  
  15. With a piece of hardwood or a brass drift which will just clear the outer bearing cup, drive the inner bearing cone and inner seal out of the wheel hub.
  16.  
  17. Wash all the old grease or axle lubricant out of the wheel hub, using a suitable solvent.
  18.  
  19. Wash the bearing cups and rollers, then inspect them for pitting, galling, and uneven wear patterns. Inspect the roller for end wear.
  20.  
  21. If the bearing cups are to be replaced, drive them out with a brass drift. Install the new cups with a block of wood and hammer or press them in.
  22.  
  23. If the bearing cups are properly seated, a 0.0015 in. (0.038mm) feeler gauge will not fit between the cup and the wheel hub. The gauge should not fit beneath the cup. Check several places to make sure the cups are squarely seated.
  24.  
  25. Pack each bearing cone and roller with a bearing packer or in the manner previously outlined in General Information & Maintenance for the front wheel bearings on 2WD trucks. Use a multi-purpose wheel bearing grease.
  26.  
  27. Place the inner bearing cone and roller assembly in the wheel hub. Install a new inner seal in the hub with a seal installation tool.
  28.  
  29. Install the wheel.
  30.  
  31. Install the adjusting nut. For bearing adjustment proceed as followed:
    1. While rotating the wheel, tighten the adjusting nut until a slight drag is felt. Then, back off the nut 1 / 6 turn. This should give free rotation and little or no end-play.
    2.  
    3. Install the lockring.
    4.  
    5. Install the outer nut. MAKE SURE THAT THE ADJUSTING NUT DOES NOT TURN WHILE TIGHTENING THE OUTER NUT. Tighten the outer nut to 35-65 ft. lbs. (47-88 Nm).
    6.  
    7. Bend one tab of the lockring inward to secure the adjusting nut and one tab outward to secure the outer nut. These tabs must be bent securely against a flat on each nut.
    8.  
    9. Install the axle shaft and new gasket or seal.
    10.  

  32.  
  33. Install the brake drum.
  34.  
  35. Remove the stands, lower the truck.
  36.  

1985-88 MODELS
  1. Set the parking brake and loosen the axle shaft bolts.
  2.  
  3. Raise the rear wheels off the floor and place jackstands under the rear axle housing so that the axle is parallel with the floor.
  4.  
  5. Remove the axle shaft bolts.
  6.  
  7. Remove the axle shaft and gaskets.
  8.  



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Fig. Fig. 18: Full floating axle, single rear hub assembly-locknut type

  1. With the axle shaft removed, remove the gasket from the axle shaft flange studs.
  2.  
  3. Bend the lockwasher tab away from the locknut, and then remove the locknut, lockwasher, and the adjusting nut.
  4.  
  5. Remove the outer bearing cone and pull the wheel straight off the axle.
  6.  
  7. With a piece of hardwood or a brass drift which will just clear the outer bearing cup, drive the inner bearing cone and inner seal out of the wheel hub.
  8.  
  9. Wash all the old grease or axle lubricant out of the wheel hub, using a suitable solvent.
  10.  



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Fig. Fig. 19: Lock wedge position on rear wheel hub

  1. Wash the bearing cups and rollers, then inspect them for pitting, galling, and uneven wear patterns. Inspect the roller for end wear.
  2.  
  3. If the bearing cups are to be replaced, drive them out with a brass drift. Install the new cups with a block of wood and hammer or press them in.
  4.  
  5. If the bearing cups are properly seated, a 0.0015 in. (0.038mm) feeler gauge will not fit between the cup and the wheel hub. The gauge should not fit beneath the cup. Check several places to make sure the cups are squarely seated.
  6.  
  7. Pack each bearing cone and roller with a bearing packer or in the manner previously outlined for the front wheel bearings in General Information & Maintenance on 2WD trucks. Use a multi-purpose wheel bearing grease.
  8.  
  9. Place the inner bearing cone and roller assembly in the wheel hub. Install a new inner seal in the hub with a seal installation tool.
  10.  
  11. Install the wheel.
  12.  
  13. Install the adjusting nut. Proceed as follows to adjust the wheel bearings:
    1. While rotating the wheel, tighten the adjusting nut to 120-140 ft. lbs. (162-189 Nm).
    2.  
    3. Back off the nut 1 / 3 turn (120°). This will provide 0.001-0.008 in. (0.02-0.20mm) end-play.
    4.  
    5. Install the lockring onto the spindle keyway.
    6.  

  14.  
  15. Install the axle shaft and new gasket.
  16.  
  17. Remove the stands, lower the truck.
  18.  

 
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