Chrysler Full-Size Vans 1967-1988 Repair Guide

Axle Shafts and Bearings

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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 " 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. Through the access hole in the axle shaft flange, remove the axle shaft retaining nuts. 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.  


CAUTION
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.

  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. Remainder of installation is the reverse of removal.
  12.  

Chrysler 8 3 / 8 ", 9 1 / 4 " and 9 1 / 4 " HD Axles

See Figures 1 through 17



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Fig. Fig. 1: Exploded view of the 8 3/8 inch drive axle



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Fig. Fig. 2: Exploded view of the 9 1/4 inch and HD drive axle



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Fig. Fig. 3: Removing the axle bearing and seal from a 8 3/8 inch or a 9 1/4 inch standard drive axle



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Fig. Fig. 4: Removing the axle bearing and seal from a 9 1/4 inch HD drive axle



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Fig. Fig. 5: Apply sealant to the axle cover as shown



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Fig. Fig. 6: Except for the top center bolt, remove all other axle cover retaining bolts



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Fig. Fig. 7: Loosen the top center bolt and gently pry the cover loose allowing the fluid to drain



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Fig. Fig. 8: Remove the top center bolt and the axle cover



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Fig. Fig. 9: Cover the differential gears with a rag and scrape away the old cover gasket material



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Fig. Fig. 10: Rotate the differential around to gain access to the pinion shaft retaining screw. Loosen ...



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Fig. Fig. 11: ... and remove the screw from the differential to free the pinion shaft (arrows)



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Fig. Fig. 12: Slide the pinion shaft up, and remove it from the differential



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Fig. Fig. 13: Push in on the axle, and using a magnet, withdraw the C-lock from the end of the axle



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Fig. Fig. 14: Slowly slide the axle out of the axle tube being careful not to damage the seal, if necessary



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Fig. Fig. 15: View of the drive axle seal (arrow) with the axle shaft removed



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Fig. Fig. 16: Use an axle seal puller to pry the old seal from the tube



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Fig. Fig. 17: Install the new axle seal using a seal installation driver of the proper size

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

  1. Jack up the vehicle and remove the rear wheels.
  2.  
  3. Clean all dirt from the housing cover and remove the housing cover to drain the lubricant.
  4.  
  5. Remove the brake drum.
  6.  
  7. Rotate the differential case until the differential pinion shaft lockscrew can be removed. Remove the lockscrew and pinion shaft.
  8.  
  9. Push the axle shafts toward the center of the vehicle and remove the C-locks from the grooves on the axle shafts.
  10.  
  11. Pull the axle shafts from the housing, being careful not to damage the bearing which remains in the housing.
  12.  
  13. Inspect the axle shaft bearings and replace any doubtful parts. Whenever the axle shaft is replaced, the bearings should also be replaced.
  14.  
  15. Remove the axle shaft seal from the bore in the housing, using the button end of the axle shaft.
  16.  
  17. Remove the axle shaft bearing from the housing. On the 8 3 / 8 " and 9 1 / 4 " axle, use a slide hammer and adapter. On the 9 1 / 4 " HD axle, use a puller such as C-4828. Do not reuse the bearing or the seal.
  18.  
  19. Check the bearing shoulder in the axle housing for imperfections. These should be corrected with a file.
  20.  
  21. Clean the axle shaft bearing cavity.
  22.  
  23. 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.
  24.  
  25. Install the axle shaft bearing seal. It should be seated beyond the end of the flange face.
  26.  
  27. 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.
  28.  
  29. 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.
  30.  
  31. Install the differential pinion shaft through the case and pinions. Install the lockscrew and secure it in position.
  32.  
  33. Clean the housing and gasket surfaces. Install the cover and a new gasket. Refill the axle with the specified lubricant.
  34.  

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

Chrysler 9 5 / 8 " Axle
  1. Remove the axle shaft flange nuts.
  2.  
  3. Install puller screws in the threaded holes provided and tighten the screws to loosen the shaft.
  4.  

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.  
  3. Installation is the reverse of removal. Always use a new gasket coated with sealer. Torque the flange nuts to 30-35 ft. lbs.
  4.  

Dana 60, 60HD and 70 Axles

See Figure 18

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Fig. Fig. 18: Exploded view of the Dana 60 and 60HD drive axle-Dana 70 drive axle is similar

1967-84 MODELS
  1. Remove the axle shaft flange nuts and washers.
  2.  
  3. Rap the axle shafts sharply in the center of the flange with a hammer to free the dowels.
  4.  
  5. Remove the tapered dowels and axle shafts. Some models are equipped with bolts rather than dowels.
  6.  
  7. Clean the gasket area with solvent and install a new flange gasket.
  8.  
  9. Install the axle shaft into the housing.
  10.  
  11. If the axle has an outer wheel bearing seal, install new gaskets on each side of the seal mounting flange.
  12.  
  13. Install the tapered dowels, lockwashers, and nuts. Torque the nuts to 40-70 ft.lbs. with 7 / 16 " studs and 65-105 ft.lbs. with 1 / 2 ". Some axles have bolts instead of studs and tapered dowels. Bolt torque is 45-75 ft.lbs.
  14.  

1985-88 MODELS
  1. Remove the axle shaft flange locknuts and washers, or bolts.
  2.  
  3. On axles with locknuts, rap the axle shafts sharply in the center of the flange with a hammer to free the dowels.
  4.  
  5. Remove the tapered dowels and/or axle shafts.
  6.  
  7. Clean the gasket area with solvent and install a new flange gasket.
  8.  
  9. Install the axle shaft into the housing.
  10.  
  11. If the axle has an outer wheel bearing seal, install new gaskets on each side of the seal mounting flange.
  12.  
  13. Install the tapered dowels, lockwashers, and nuts or Durlock® bolts. Torque the 7 / 16 -20 nuts to 40-70 ft. lbs.; the 1 / 2 -20 nuts to 65-105 ft. lbs.; the Durlock® bolts to 60 ft. lbs.
  14.  

 
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