Durango, 2001-2005

Removal & Installation

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Bearings



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove the half shaft from vehicle.
  4.  
  5. Remove the skid plate, if equipped.
  6.  
  7. Clean the axle seal area.
  8.  
  9. Remove axle shaft O-ring.
  10.  
  11. Remove the axle shaft.
  12.  
  13. Remove the axle shaft seal.
  14.  
  15. Install the axle shaft bearing remover C-4660-A, or equivalent, in the bearing. Then tighten the nut to spread the remover in the bearing.
  16.  
  17. Install the bearing remove cup, bearing and nut. Then tighten the nut to draw the bearing out.
  18.  
  19. Inspect the axle shaft tube bore for roughness and burrs. Remove as necessary.

    Click image to see an enlarged view

    Fig. Removing the axle shaft bearing (1) using remover C-4660-A (3) and nut (2)

    Removing the axle shaft bearing (1) using remover C-4660-A (3) and nut (2)
  20.  

To install:

  1. Wipe the axle shaft tube bore clean.
  2.  
  3. Install the axle shaft bearing with installer 5063 and handle C-4171, or equivalent.
  4.  
  5. Install a new axle shaft seal with installer 8402 and handle C-4171, or equivalent.
  6.  
  7. Install the axle shaft and half shaft.
  8.  

Halfshaft



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Skid plate, if equipped
     
    Front wheel
     
    Split pin
     
    Nut lock
     
    Spring washer
     
    Hub nut
     
    Brake caliper and rotor
     
    Wheel speed sensor, if equipped
     
    Wheel bearing and hub assembly
     

  4.  
  5. Pry the inner tripod joint out of the differential and remove the axle halfshaft.
  6.  

To install:

  1. Install the axle halfshaft so that the snapring is felt to seat in the joint housing groove.
  2.  
  3. Install or connect the following:

    Wheel bearing and hub assembly
     
    Wheel speed sensor, if equipped
     
    Brake caliper and rotor
     
    Hub nut. Tighten the nut to 180 ft. lbs. (244 Nm).
     
    Spring washer
     
    Nut lock
     
    Split pin
     
    Front wheel
     
    Skid plate, if equipped

    Click image to see an enlarged view

    Fig. To separate the halfshaft from the hub, remove the cotter pin, nut lock and spring washer from the axle shaft

    To separate the halfshaft from the hub, remove the cotter pin, nut lock and spring washer from the axle shaft
     

  4.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. With vehicle in neutral, position vehicle on hoist.
  4.  
  5. Remove skid plate, if equipped.
  6.  
  7. Remove hub nut from the halfshaft.
  8.  
  9. Remove brake caliper and rotor.
  10.  
  11. Remove wheel speed sensor if equipped.
  12.  
  13. Remove hub bearing bolts from the knuckle.
  14.  
  15. Remove hub bearing and brake shield from knuckle.
  16.  
  17. Support halfshaft at the CV-joint housings.
  18.  
  19. Position two pry bars behind the inner C/V housing and disengage the CV-joint from the axle.
  20.  
  21. Remove halfshaft through the knuckle.

    Click image to see an enlarged view

    Fig. Assembling the axle shaft removal tool 8420A

    Assembling the axle shaft removal tool 8420A
  22.  

To install:

  1. Apply a light coating of wheel bearing grease on the axle splines.
  2.  
  3. Insert halfshaft through the steering knuckle and onto the axle. Verify shaft snapring engages with the groove on the inside of the joint housing.
  4.  
  5. Clean hub bearing bore and hub bearing mating surface. Lightly coat mating surfaces with grease.
  6.  
  7. Install hub bearing onto the axle halfshaft and into steering knuckle. Tighten hub bearing bolts to 163 Nm (120 ft. lbs.).
  8.  
  9. Install wheel speed sensor, if equipped.
  10.  
  11. Install brake rotor and caliper adapter with caliper.
  12.  
  13. Install halfshaft nut. Apply brakes and tighten shaft nut to 185 ft. lbs. (251 Nm).
  14.  
  15. Install skid plate, if equipped.
  16.  

Seal



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Front axle shafts
     
    Differential cover
     
    Differential and ring gear assembly
     
    Axle seals
     

  4.  

To install:

  1. Press the axle seals into the differential housing with Turnbuckle 6797 and Disc set 8110.
  2.  
  3. Install or connect the following:

    Differential and ring gear assembly. Tighten the bearing cap bolts to 45 ft. lbs. (61 Nm).
     
    Differential cover. Tighten the bolts to 30 ft. lbs. (41 Nm).
     
    Front axle shafts
     

  4.  
  5. Fill the axle assembly with gear oil and check for leaks.
  6.  

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove half shaft and axle shaft.
  4.  
  5. Remove axle shaft seal with a small pry bar.
  6.  

To install:

  1. Wipe axle shaft tube bore clean.
  2.  
  3. Install new axle shaft seal with Installer 8402 and Handle C-4171.
  4.  
  5. Install axle shaft and half shaft.
  6.  

 
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