Chrysler Full-Size Vans 1989-1998 Repair Guide

Axle Shaft, Bearing and Seal

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 and 22



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Fig. Fig. 1: Loosen the cover bolts and remove all of them, except two at the top and two at the bottom



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Fig. Fig. 2: Use a prybar to carefully pry the cover from the axle housing



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Fig. Fig. 3: When performed properly, gear fluid should flow into the drain pan without causing a mess



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Fig. Fig. 4: Once the gear oil drains, remove the remaining bolts, then remove the axle housing cover



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Fig. Fig. 5: Any time the differential cover is removed, inspect the gears for damage (arrow) and replace as necessary



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Fig. Fig. 6: Rotate the differential case so that the pinion gear shaft lock screw is accessible



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Fig. Fig. 7: Remove the lock screw ...



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Fig. Fig. 8: ... push the pinion gear shaft up from the bottom ...



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Fig. Fig. 9: ... and remove it from the differential case



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Fig. Fig. 10: Once the shaft is removed, the C-clip is visible. Push the axle in slightly to remove the C-clip ...



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Fig. Fig. 11: ... and the axle can then be removed from the housing



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Fig. Fig. 12: Take care not to damage the seal or bearing during axle removal



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Fig. Fig. 13: When installing the axle shaft lock screw, always use a threadlocking compound to hold the screw in place



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Fig. Fig. 14: Use a scraper to remove gasket material from the axle housing ...



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Fig. Fig. 15: ... and the axle housing cover



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Fig. Fig. 16: Wipe the cover clean, as sealer will not adhere to an oily surface



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Fig. Fig. 17: Apply sealer in a continuous bead around the cover



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Fig. Fig. 18: When installing the axle cover, always replace the metal identification tag. This tag provides the only means of externally identifying the axle ratio



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Fig. Fig. 19: The rear axle fluid can be checked after removing a plug in the rear cover



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Fig. Fig. 20: Fill the axle housing through the filler hole with the proper type and amount of gear oil



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Fig. Fig. 21: When checking the gear oil level, stick your finger inside the filler/inspection hole



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Fig. Fig. 22: The gear oil level should be 3/8in. (10mm) below the bottom of the filler hole

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Ensure that the transmission is in Neutral.
  4.  
  5. Remove wheels.
  6.  
  7. Remove brake drums.
  8.  
  9. Clean all foreign material from housing cover area.
  10.  
  11. Loosen all housing cover bolts, and remove all but two bolts on the top and two on the bottom.
  12.  
  13. Use a prybar to pry the cover loose from the axle.
  14.  
  15. Allow the gear oil to drain from the housing and axle shaft tubes.
  16.  
  17. Remove the axle housing cover.
  18.  
  19. Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and pinion mate gear shaft from the differential case.
  20.  
  21. Remove the axle shaft.
  22.  
  23. Remove the axle shaft seal from the end of the axle tube with a small prybar.
  24.  

The seal and bearing can be removed at the same time with the bearing removal tool.

  1. Remove the axle shaft bearing from the axle tube using an appropriate puller.
  2.  

To install:

Always install a new axle bearing seal.

  1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube.
  2.  
  3. Install the axle shaft bearing. Ensure that the bearing part number is facing outward. Verify that the bearing is installed straight and flush with the axle tube when fully seated.
  4.  
  5. Inspect axle shaft seal for leakage or damage
  6.  
  7. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced.
  8.  
  9. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines.
  10.  

Use care to prevent shaft splines from damaging axle shaft seal lip.

  1. Insert C-clip lock in end of axle shaft.
  2.  
  3. Push axle shaft outward to seat C-clip lock in side gear.
  4.  
  5. Insert pinion mate shaft into the differential case and through the thrust washers and pinion gears.
  6.  
  7. Align the hole in the shaft with the hole in the differential case, and install the lock screw with Loctite on the threads. Tighten the lock screw to 8 ft. lbs. (11 Nm).
  8.  
  9. Install cover and fill the differential with gear oil.
  10.  
  11. Install the brake drum.
  12.  
  13. Install the wheel and tire
  14.  
  15. Lower the vehicle.
  16.  

 
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