Axle Disassembly

Fig. 1 Chrysler rear drive axle exploded view. 1980---81 w/8-3/8 inch ring gear:

Fig. 2 Chrysler drive axle exploded view:

Fig. 3 Differential pinion shaft removal:

1. Raise and support rear of vehicle and remove propeller shaft.
2. Remove rear cover and gasket and drain lubricant.
3. Rotate differential to gain access to differential pinion shaft lock screw, and remove lock screw and pinion shaft.

Fig. 4 Axle shaft ``C'' lock removal:

Fig. 5 Ring gear runout check:

Fig. 6 Marking side bearing caps:

4. Push axle shafts toward center of housing, and remove axle shaft "C" locks and the axle shafts.
5. Check ring gear runout and ring gear and pinion backlash with suitable dial indicator to aid assembly. If original ring gear and pinion are reused, backlash should be adjusted to measured value in order to maintain established gear tooth contact pattern.
6. Mark position of differential side bearing caps to aid assembly, remove side bearing adjuster locks, then loosen but do not remove side bearing cap bolts.

Fig. 7 Typical side bearing adjustment:

Fig. 8 Measuring pinion rotating torque (bearing preload):

Fig. 9 Typical companion flange removal:

7. Insert suitable tool through each axle tube, and loosen side bearing adjusters.
8. Support differential assembly and remove side bearing caps, then the differential assembly.
9. Place side bearing outer races with respective bearing caps to ensure proper assembly.
10. Measure pinion rotating torque (bearing preload) with suitable torque wrench. If preload is not within specifications, or if endplay is present, pinion must be removed.
11. Hold companion flange with suitable tool and remove pinion nut and washer.
12. Remove companion flange with suitable puller, then pry pinion seal from housing.
13. Temporarily install rear cover using 2 bolts, then drive pinion from bearings taking care not to damage threaded end of pinion shaft. Pinion removal will cause excessive impact loading of front pinion bearing assembly. If pinion removal is necessary, front bearing must be replaced.
14. Press rear bearing from pinion using suitable spacers, then remove depth adjusting shim, if equipped.
15. Remove pinion bearing races using suitable pullers or brass drift and hammer, and retain pinion depth adjusting shims located under rear bearing race, if equipped.
16. Inspect components as outlined in "Cleaning and Inspection," keeping components in order, and replace as needed. Components that are reused must be installed in original position.