Chrysler Full-Size Trucks 1997-2000 Repair Guide

Axle Shaft, Bearing and Seal

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REMOVAL & INSTALLATION



8 1 / 4 , 9 1 / 4 Axles

NOTE
The following procedure is written for removal of one axle, but it applies to both.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Ensure that the transmission is in Neutral .
  4.  
  5. Remove the wheel.
  6.  
  7. Remove the brake drum.
  8.  
  9. Clean all foreign material from the 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.
  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 .
  20.  
  21. Remove the pinion mate gear shaft from the differential case.
  22.  
  23. Push the axle in towards the center of the vehicle and remove the C-lock from the groove on the axle shaft.
  24.  
  25. Pull out and remove the axle shaft.
  26.  
  27. Remove the axle shaft seal from the end of the axle tube with a small prybar.
  28.  


NOTE
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:


NOTE
Always install a new axle bearing seal.

  1. Clean the inside of the axle housing, removing any swarf or foreign matter. Some units have a magnet in the base to catch metal filings.
  2.  
  3. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube.
  4.  
  5. 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.
  6.  
  7. Inspect axle shaft seal for leakage or damage
  8.  
  9. 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.
  10.  
  11. Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines.
  12.  


NOTE
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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Fig. Exploded view of a typical rear axle-8 1 / 4 , 9 1 / 4 shown



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



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



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Fig. Rotate the differential case so that the pinion gear shaft lock screw is accessible, and then remove it



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Fig. Push the pinion gear shaft up from the bottom and remove it



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Fig. Push the axle in slightly to remove the C-clip-



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



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



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Fig. Removing the wheel bearing seal



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Fig. Clean metal particles off the magnet, if fitted



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Fig. Be sure that the splines do NOT damage seal or bearings when installing



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



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



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Fig. Apply sealer in a continuous bead around the cover



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Fig. 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. Fill the axle housing through the filler hole with the proper type and amount of gear oil. Proper level is 3 / 8 in. (10mm) below the bottom of the hole

248 RBI, 267 RBI, 286 RBI Axles

NOTE
The following procedure is written for removal of one axle shaft, but it applies to both.

  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Ensure that the transmission is in Neutral .
  4.  
  5. Remove the wheel.
  6.  
  7. Remove the brake drum.
  8.  
  9. Clean all foreign material from the housing cover area.
  10.  
  11. Loosen all housing cover bolts, and remove all except the 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.
  16.  
  17. Remove the axle housing cover.
  18.  
  19. Remove the axle shaft flange bolts.
  20.  
  21. Remove the axle.
  22.  
  23. Remove the lock wedge and adjustment nut.
  24.  
  25. Remove the hub assembly. The outer axle bearing will slide out as the hub is removed.
  26.  
  27. Remove the inner grease seal.
  28.  
  29. Remove the bearing cups.
  30.  

To install:

  1. Clean all parts thoroughly.
  2.  
  3. Install the bearing cups. Apply lubricant to the surface area.
  4.  
  5. Install the inner axle bearing.
  6.  
  7. Install a new bearing grease seal.
  8.  
  9. Apply a coating of multi-purpose NLGI Grade 2, EP lubricant to the axle.
  10.  


WARNING
Use care to prevent the grease seal from contacting the axle tube spindle threads during installation.

  1. Carefully slide the hub onto the axle.
  2.  
  3. Install the outer axle bearing.
  4.  
  5. Install the hub bearing adjustment nut.
  6.  
  7. Tighten the adjustment nut to 120-140 ft. lbs. (163-190 Nm) while rotating the wheel.
  8.  
  9. Loosen the adjustment nut 1 / 8 turn at a time to provide 0.001-0.010 in. wheel bearing endplay.
  10.  
  11. Tap the locking wedge into the spindle key-way and adjustment nut. Ensure that the locking wedge is installed in a new position.
  12.  

 
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