Chrysler Full-Size Trucks 1997-2000 Repair Guide

Axle Shaft, Bearing and Seal

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REMOVAL & INSTALLATION



194 FIA Axle
  1. Place the transmission in NEUTRAL .
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the C/V driveshaft(s).
  6.  
  7. Remove the shock absorber if removing the right axle shaft.
  8.  
  9. Remove the skidplate if removing the left axle shaft.
  10.  
  11. Clean all foreign matter from the housing cover area.
  12.  
  13. Remove the housing cover, draining the lubricant into a suitable container.
  14.  
  15. Remove the E-clip retaining the axle shaft on the side you wish to remove.
  16.  
  17. Remove the axle shaft. Take care to avoid damaging the bearing and seal that will remain in the axle shaft tube.
  18.  
  19. Pry out the axle shaft seal with a suitable tool.
  20.  
  21. Remove the bearing with a suitable puller.
  22.  
  23. Inspect the roller bearing contact surface on the axle shaft for signs of brinelling, galling or pitting. Replace the shaft and bearing if any of these conditions exist.
  24.  
  25. Installation is the reverse of removal. Always use a new seal and lubricate the seal lips before installing the shaft.
  26.  

C205F Axle
  1. Place the transmission in NEUTRAL .
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the C/V driveshaft.
  6.  
  7. Remove the skidplate if fitted.
  8.  
  9. Clean all foreign matter from the axle seal area.
  10.  
  11. Remove the axle shaft with a slide hammer. Take care to avoid damaging the bearing and seal which will remain in the axle shaft tube.
  12.  
  13. Pry out the axle shaft seal with a suitable tool.
  14.  
  15. Remove the bearing with a suitable puller.
  16.  
  17. Installation is the reverse of removal. Always use a new seal and lubricate the seal lips before installing the shaft. Push firmly on the axle shaft until the axle shaft snap-ring passes completely through the side gear and engages the snap-ring groove.
  18.  

216 FBI, 248 FBI Axles
  1. Place the transmission in NEUTRAL .
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the brake caliper and rotor.
  8.  
  9. Remove the ABS wheel speed sensor, if fitted.
  10.  
  11. Remove the axle hub nut cotter pin and the nut.
  12.  
  13. Remove the hub-to-knuckle bolts. Remove the hub bearing from the steering knuckle and axle shaft.
  14.  
  15. Remove the brake dust shield.
  16.  
  17. Remove the axle shaft from the housing. Be sure to avoid damaging the oil seal.
  18.  
  19. To service the bearings and seals, the differential must be removed. This requires the use of a spreader to enlarge the differential housing.
    1. Note the orientation of the installation reference letters stamped on the bearing caps and housing machined sealing surface.
    2.  
    3. Remove the differential bearing caps.
    4.  
    5. Install the spreader and enlarge the housing to remove the differential.
    6.  

  20.  


WARNING
Do NOT spread the unit over 0.020 in. (0.50mm).

  1. Remove the bearings from the differential.
  2.  
  3. Remove the oil seals from the differential housing.
  4.  

  1. Installation is the reverse of removal. Tighten differential bearing cap bolts to 80 ft. lbs. (109 Nm). Other torque ratings are:

    Hub bearing-to-knuckle 125 ft. lbs. (170 Nm)
     
    Axle nut: 175 ft. lbs. (237 Nm)
     

  2.  



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Fig. Removing the hub-to-knuckle bolts



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Fig. Bearing cap installation reference letters

AXLE SHIFT MOTOR
  1. Disconnect the vacuum and wiring connector from the shift housing.
  2.  
  3. Remove the indicator switch.
  4.  
  5. Remove the shift motor housing cover, gasket and shield.
  6.  

To install:

  1. Install the shift motor housing gasket and cover. Ensure the shift fork is correctly guided into the shift collar groove.
  2.  
  3. Tighten the shield bolts to 8 ft. lbs. (11 Nm).
  4.  



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Fig. Shift motor components

AXLE SHAFT U-JOINT

This component is disassembled in the same manner as described under "Driveshaft and U-Joints."



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Fig. Axle shaft U-joint assembly

 
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