Installation

INSTALLATION

Special Tools:










1. Install new axle seal(s) (1) using (9223A) (2) if a new seal is required.

NOTE: Always use (9099) when installing half shaft into the transaxle. If the Seal Protector is new please split at seam before using.

NOTE: Use care when installing halfshaft to axle assembly. The halfshaft installation angle should be minimized to avoid damage to seal upon installation.






NOTE: While raising rear axle reposition rear drive shaft to rear axle flange.

2. Install new circlip(s), on halfshafts (3).
3. Raise axle just enough to install both halfshafts one at a time. Be careful not to damage axle seals using (9099) (1). Shift axle assembly in one direction, compressing one halfshaft while installing the other.






NOTE: Use care when installing halfshaft to axle assembly. The halfshaft installation angle should be minimized to avoid damage to seal upon installation.

4. Using new circlip(s), install halfshaft (1) to rear axle assembly. Use care not to damage axle seals (2). Verify proper installation by pulling outward on joint by hand.





5. Raise rear axle assembly into position. Align propeller shaft index marks (3) and start propeller shaft coupler-to-axle bolt/nuts by hand.





6. Install two rear axle-to-crossmember bolts (1) and torque to 220 Nm (162 ft. lbs.).
7. Install rear axle front mount isolator (1) as shown and torque bolt/nut to 65 Nm (48 ft. lbs.).





8. Again verify halfshaft inner joints are fully engaged to axle assembly.
9. Remove transmission jack (1).
10. If used, remove screw-type under-hoist jack stands (2).





11. Tighten propeller shaft coupler-to-axle flange bolt/nuts refer to[1][2]Drive/Propeller Shaft for the appropriate specification.





12. Using a 14mm hex, remove rear axle fill plug (1). Fill axle with 1.4L (1.5 qts.) of Mopar(R) 75W-140 Synthetic Gear AND Axle Lubricant. Install fill plug and torque to 60 Nm (44 ft. lbs.).