DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA

DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Worn wheel bearing. 2. Replace bearing.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct

fluid type and quantity.

2. End-play in pinion. 2. Replace axle assembly.

3. Excessive gear backlash 3. Replace axle assembly.

between the ring gear and pinion.

4. Loose pinion yoke nut. 4. Replace axle assembly.

5. Scuffed gear tooth contact 5. Replace axle assembly.

surfaces.

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1. Cross member cradle dampers 1. Positioned cross member
Axle Whine
not positioned correctly. cradle dampers correctly.

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.

2. Worn axle shaft seals. 2. Replace seals.

3. Worn pinion seal. 4. Replace seal.

4. Worn/scored yoke. 5. Replace axle assembly.

5. Axle cover not properly sealed. 6. Replace axle assembly.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correct

fluid type and quantity.

3. Bearing pre-loads too high. 3. Replace axle assembly.

4. Insufficient ring gear backlash. 4. Replace axle assembly.

Gear Teeth Broke 1. Overloading. 1. Replace axle assembly.

2. Erratic clutch operation. 2. Replace axle assembly.

3. Ice-spotted pavement. 3. Replace axle assembly.

4. Improper adjustments. 4. Replace axle assembly.

DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA >
GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper offset and squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type
of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate
the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes greatly check for:

Insufficient lubricant

Differential side and pinions gears, usually do not cause noise during straight-ahead driving, when the
gears are unloaded. The side gears are loaded during turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.

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DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA >
BEARING NOISE

Bearing noise can be either a whining or a growling sound.

Pinion bearings have a constant high pitch noise, because it rotates at a faster rate. This noise
changes with vehicle speed.

Differential bearings usually produce a low pitch noise. The differential bearing noise is constant and
varies only with vehicle speed.

DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA >
LOW SPEED KNOCK

Low speed knock is generally caused by:

Worn U-joints/CV joint

Worn side-gear thrust washers

Worn pinion shaft bore

DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA >
VIBRATION

Vibration at the rear of the vehicle is usually caused by:

Damaged drive shaft

Missing drive shaft balance weight(s)

 Worn or out-of-balance wheels

Loose wheel lug nuts

Worn U-joints/CV joint

Loose/broken springs

Loose pinion gear nut

Excessive pinion yoke run out

Check for loose or damaged front-end components or engine/transmission mounts. These components
can contribute to what appears to be an axle vibration. Also look at engine accessories, brackets and
drive belts.

NOTE:

All driveline components should be examined before starting any repair.

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DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FRONT AXLE - 195FIA >
DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged, can be caused by:

High engine idle speed

Transmission shift operation

Loose engine/transmission/transfer case mounts

Worn U-joints/CV joint

Loose spring mounts

Loose pinion gear nut and yoke

Excessive ring gear backlash

Excessive side gear to case clearance

To determined the source of a snap/clunk noise, raise vehicle on a hoist with the wheels free to rotate.
Have a helper shift the transmission into gear and listen for the noise.

STANDARD PROCEDURE > STANDARD PROCEDURE - FLUID DRAIN AND FILL

Fig 1: Rear Axle Drain Plug & Fill Plug

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1. Drive the vehicle until the differential lubricant is at the normal operating temperature.

2. With vehicle in neutral, position and raise vehicle on hoist.

3. Remove rear axle drain plug (2) and drain lubricant completely from the axle.

4. Install drain plug and tighten to 35 N.m (26 ft. lbs).

5. Remove fill plug (1) and fill rear axle to the bottom of the fill hole. Refer to CAPACITIES AND
RECOMMENDED FLUIDS, SPECIFICATIONS .

6. Install fill plug and tighten to 35 N.m (26 ft. lbs).

SPECIFICATIONS > SPECIFICATIONS

DESCRIPTION SPECIFICATION
 Axle Ratio 3.09/3.27/3.45

Ring Gear Diameter 195 mm (7.67 in.)

TORQUE SPECIFICATIONS

DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENTS

Fill and Drain Plugs 35 26 -

Front Axle Cover Bushing Bolt 115 85 -

Front Axle Pinion Nose Bushing

115 85 -
Bolt

Front Axle Tube Bushing Bolt 61 45 -

Front Frame Damper Bolts 61 41 -

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REMOVAL > REMOVAL
Fig 1: Rear Axle Drain Plug & Fill Plug

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1. With vehicle in neutral, position vehicle on hoist.

2. Remove skid plate, if equipped.

3. Remove differential housing drain plug (2) and drain the fluid.

4. Install the drain plug and torque to 35 N.m (26 ft. lbs.).

CAUTION:

Remove axle vent tube prior to removing axle. Failure to remove vent tube will allow
axle fluid to saturate the vent and cause reduced or improper axle venting resulting
in axle damage.

5. Remove axle vent tube from axle.

 Fig 2: Propeller Shaft, Pinion Flange & Reference Marks

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6. Remove the wheel and tire assemblies.

7. Mark front propeller shaft (1) and pinion flange (2) for installation reference. Remove propeller
shaft from pinion flange.
 Fig 3: Hub Nut & Half Shaft

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8. Remove both brake calipers and hang to the side. Refer to CALIPER, DISC BRAKE,
REMOVAL .

9. Remove hub nuts (1) from half shafts (2).

 Fig 4: Tie Rod End Nut & Stabilizer Bar Link Bolts

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10. Remove tie rod end nut (1).

11. Remove stabilizer bar link bolts (7) from lower control arms.
 Fig 5: Outer Tie Rod Ends, Knuckles & Ball Joint Remover

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12. Separate the outer tie rod ends (3) from the knuckles (2) with Ball Joint Remover (special tool
#8677, Remover, Ball Joint) (1).
 Fig 6: Ball Joint Press, Upper Ball Joint & Knuckle

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13. Remove the upper ball joint nuts.

14. Separate the upper ball joints (2) from the knuckles (3) using Ball Joint Press (special tool
#C-4150A, Press, Ball Joint) (1).
 Fig 7: Knuckle & Half Shaft

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15. Pull out on the steering knuckles (2) and push the half shafts (1) out of the knuckles.

16. With a pry bar remove both half shafts (1) from the axle.
 Fig 8: Front Axle Cover Bushing Bolt & Pinion Nose Bushing Bolt

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17. Support axle with a lift/jack.

18. On Diesel applications, remove the lower oil pan to remove mounting bolt. Refer to PAN, OIL,
REMOVAL .

19. Loosen the front axle cover bushing bolt (2) and front axle pinion nose bushing bolt (1) from
crossmember.
 Fig 9: Nut And Bolt, Front Axle Tube Bushing & Bolts

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20. Remove nut and bolt (1) from front axle tube bushing (2) bracket.

21. Remove bolts (1) from front axle tube bushing bracket (2).

22. Remove bolts (3) from frame dampener.

 Fig 10: Front Axle

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NOTE:

To remove the axle, tilt the front side of the axle downward while maneuvering the
axle bracket. Then lower the axle and slide it to the RH side of the vehicle to clear
the front axle cover mounting bracket.

23. Remove the axle (1) from the vehicle.

INSTALLATION > INSTALLATION

Fig 1: Front Axle

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1. Lift the axle into vehicle.

 Fig 2: Nut And Bolt, Front Axle Tube Bushing & Bolts

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2. Install the front axle tube bushing mounting bolt and nut (1) in the RH axle bracket (2) and
tighten to the proper specification. Refer to SPECIFICATIONS .

3. Install frame dampener (4) and bolts (3) and tighten to the proper specification. Refer to
SPECIFICATIONS .
 Fig 3: Front Axle Cover Bushing Bolt & Pinion Nose Bushing Bolt

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4. Install the front axle cover bushing bolt (2) and front axle pinion nose bushing bolt (1) and
tighten to the proper specification. Refer to SPECIFICATIONS .

5. Install front axle vent tube and ensure orientation is correct. Vent Tube needs to be fully seated
to vent nipple and then can be orientated to correct position.

6. On Diesel applications, install the lower oil pan. Refer to PAN, OIL, INSTALLATION .
 Fig 4: Axle Seal Protector

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7. Using (special tool #10270, Protector, Half Shaft, Drive), install both axle shafts into the axle
carefully avoiding damage to axle seals.
 Fig 5: Knuckle & Half Shaft

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8. Install both axle shafts into the steering knuckles (2), and hub bearing.
 Fig 6: Upper Ball Joint Nuts & Steering Knuckles

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9. Install the upper ball joints into the steering knuckles (2) and tighten nuts (1) to the proper
specification. Refer to FRONT, SPECIFICATIONS .

10. Install both brake calipers. Refer to CALIPER, DISC BRAKE, INSTALLATION .
 Fig 7: Tie Rod End Nut & Stabilizer Bar Link Bolts

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11. Install the tie rod ends (1) on the steering knuckles (2) and tighten to the proper specification.
Refer to FRONT, SPECIFICATIONS .

12. Align the shock clevises (1) with the lower control arms and install the clevis brackets. Refer to
SHOCK ABSORBER, SUSPENSION, INSTALLATION .

13. Install the stabilizer bar links (1) and tighten bolts (2) to the proper specification. Refer to
FRONT, SPECIFICATIONS .
 Fig 8: Hub Nut & Half Shaft

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14. Install the half shaft (2) hub nuts (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .
 Fig 9: Propeller Shaft, Pinion Flange & Reference Marks

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15. Install the propeller shaft (1) with reference marks (3) aligned.

NOTE:

Clean propeller shaft bolts and apply Mopar Lock and Seal Adhesive or equivalent
to the threads before installation.

16. Install the propeller shaft bolts and tighten in a star pattern to the proper specification. Refer to
SPECIFICATIONS .

17. Install the front wheel and tire assemblies. Refer to WHEELS, STANDARD PROCEDURE .

18. Fill the differential with gear lubricant to the bottom of the fill hole. Refer to CAPACITIES AND
RECOMMENDED FLUIDS, SPECIFICATIONS .

19. Install fill plug and tighten to the proper specification. Refer to SPECIFICATIONS .

20. Install the skid plate, if equipped. Refer to PLATE, SKID, FRONT, INSTALLATIONPLATE, SKID,
FRONT SUSPENSION, INSTALLATION .
 21. Pump brake pedal until caliper pistons and brake pads are seated and a firm brake pedal is
obtained.

SPECIAL TOOLS > SPECIAL TOOLS

10219 - Installer, Seal

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10220 - Installer, Seal

10221 - Installer, Seal

1026 - Puller
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN,
9202CC.)
10270 - Protector, Half Shaft, Drive

6448A - Installer, Bearing/Gear

(Originally Shipped In Kit Number(s) 6947, 8667, 8837,
8867.)

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7794-A - Remover, Seal
(Originally Shipped In Kit Number(s) 6645.)

8217 - Remover, Axle Seal

(Originally Shipped In Kit Number(s) 8273CC.)

8320 - Installer, Bearing

(Originally Shipped In Kit Number(s) 8283, 8283CC, 8527,
8527CC, 8575, 8575CC, 9975.)
8677 - Remover, Ball Joint
(Originally Shipped In Kit Number(s) 8685, 8685CC, 8712,
9973, 9974, 9975.)

8866 - Installer, Bearing Cup

(Originally Shipped In Kit Number(s) 8998, 8998CC.)

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9653-1 - Remover, Bushing
(Originally Shipped In Kit Number(s) 9330, 9576, 9576-CAN,
9577, 9787.)

9653-3 - Installer, Bushing

(Originally Shipped In Kit Number(s) 9330, 9576, 9576-CAN,
9577, 9787.)

9767 - Installer, Bearing

(Originally Shipped In Kit Number(s) 9765.)

9948 - Remover/Installer, Bushing

(Originally Shipped In Kit Number(s) 9945-SUP.)
9948-3 - Nut, Special
(Originally Shipped In Kit Number(s) 9945-SUP.)

9949 - Remover, Ball Joint

(Originally Shipped In Kit Number(s) 9945.)

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C-3281 - Holder, Flange
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN,
9202CC, 9299, 9299CC, 9300A-CAN.)

C-4150A - Press, Ball Joint

(Originally Shipped In Kit Number(s) 6672, 6745.)

C-4171 - Driver Handle, Universal

(Originally Shipped In Kit Number(s) 9202, 9202A-CAN,
9202CC, 9299, 9299CC, 9300A-CAN.)

C-4171-2 - Extension, Drive Handle

(Originally Shipped In Kit Number(s) 6672, 8659.)
 C-4212F - Press, Ball Joint
(Originally Shipped In Kit Number(s) 6745, 6880, 6881,
MLR-C03.)

C-637 - Slide Hammer, Universal

(Originally Shipped In Kit Number(s) 9202.)

BUSHING, AXLE SHAFT, FRONT COVER > REMOVAL > REMOVAL

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NOTE:

Front Cover bushing shown in illustration. Rear bushing uses the same procedure.
Fig 1: Axle, Remover & Receiver

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1. Remove front axle from vehicle. Refer to REMOVAL .

2. Secure the axle in a vice.

3. Remove bushing from axle (2) with Remover (special tool #9767, Installer, Bearing) (1),
Receiver (special tool #8217, Remover, Axle Seal) (3), Remover/Installer (special tool #9948,
Remover/Installer, Bushing), and Special Long Nut (special tool #9948-3, Nut, Special) (4).

BUSHING, AXLE SHAFT, FRONT COVER > INSTALLATION > INSTALLATION

Fig 1: Bushing, Axle & Installer

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NOTE:

Front Cover bushing shown in illustration. Rear bushing uses the same procedure.

1. Install new bushing (2) in axle (3) with Installer (special tool #8866, Installer, Bearing Cup) (1)
inverted, Installer (special tool #8320, Installer, Bearing) (4), Remover/Installer (special tool
#9948, Remover/Installer, Bushing), and Special Long Nut (special tool #9948-3, Nut, Special)
(5).

2. Install the axle in the vehicle. Refer to INSTALLATION .

BUSHING, AXLE SHAFT, REAR > REMOVAL > REMOVAL

 NOTE:

Front Cover bushing shown in illustration. Rear bushing uses the same procedure.

Fig 1: Axle, Remover & Receiver

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1. Remove front axle from vehicle. Refer to REMOVAL .

2. Secure the axle in a vice.

3. Remove bushing from axle (2) with Remover (special tool #9767, Installer, Bearing) (1),
Receiver (special tool #8217, Remover, Axle Seal) (3), Remover/Installer (special tool #9948,
Remover/Installer, Bushing), and Special Long Nut (special tool #9948-3, Nut, Special) (4).

BUSHING, AXLE SHAFT, REAR > INSTALLATION > INSTALLATION

Fig 1: Bushing, Axle & Installer

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NOTE:

Front Cover bushing shown in illustration. Rear bushing uses the same procedure.

1. Install new bushing (2) in axle (3) with Installer (special tool #8866, Installer, Bearing Cup) (1)
inverted, Installer (special tool #8320, Installer, Bearing) (4), Remover/Installer (special tool
#9948, Remover/Installer, Bushing), and Special Long Nut (special tool #9948-3, Nut, Special)
(5).

2. Install the axle in the vehicle. Refer to INSTALLATION .

BUSHING, AXLE SHAFT, RIGHT > REMOVAL > REMOVAL

1. Remove front axle from vehicle. Refer to REMOVAL .

 Fig 1: Removing Bushing From Axle

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2. Secure axle in vice as shown in illustration.

3. Remove bushing from axle (3) with Press (special tool #C-4212F, Press, Ball Joint) (2),
Remover (special tool #9653-1, Remover, Bushing) (1), and Receiver (special tool #9949,
Remover, Ball Joint) (4).

BUSHING, AXLE SHAFT, RIGHT > INSTALLATION > INSTALLATION

Fig 1: Installing Axle Bushing

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1. Install new bushing (4) in axle (3) with Press (special tool #C-4212F, Press, Ball Joint) (1),
Remover (special tool #9653-3, Installer, Bushing) (5), and Receiver (special tool #9949,
Remover, Ball Joint) (2).

2. Install the axle in the vehicle. Refer to INSTALLATION .

SEAL, AXLE DRIVE SHAFT > REMOVAL > REMOVAL > RIGHT SIDE
Fig 1: Removing Right Side Axle Shaft Seal

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1. Remove halfshaft. Refer to REMOVAL .

2. Using seal remover (special tool #7794-A, Remover, Seal) (1) and slide hammer (special tool
#C-637, Slide Hammer, Universal), remove axle shaft seal (2).

3. Visually inspect halfshaft seal journal for damage (excessive seal groove, nicks, scratches,
etc.). Replace halfshaft if necessary.

SEAL, AXLE DRIVE SHAFT > REMOVAL > REMOVAL > LEFT SIDE
Fig 1: Removing Left Side Axle Shaft Seal

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1. Remove halfshaft. Refer to REMOVAL .

2. Using seal remover (special tool #7794-A, Remover, Seal) (1) and slide hammer (special tool
#C-637, Slide Hammer, Universal), remove axle shaft seal (2).

3. Visually inspect halfshaft seal journal for damage (excessive seal groove, nicks, scratches,
etc.). Replace halfshaft if necessary.

SEAL, AXLE DRIVE SHAFT > INSTALLATION > INSTALLATION > RIGHT SIDE
Fig 1: Driver Handle & Installer

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1. Using Driver Handle (special tool #C-4171, Driver Handle, Universal) (1), Drive Handle
Extension (special tool #C-4171-2, Extension, Drive Handle) and Installer (special tool
#10221, Installer, Seal) (2), and install NEW axle shaft seal. Lubricate the inside diameter with
Mopar® Gear and Axle Lubricant to protect seal during halfshaft installation.

2. Install halfshaft. Refer to INSTALLATION .

SEAL, AXLE DRIVE SHAFT > INSTALLATION > INSTALLATION > LEFT SIDE
Fig 1: Driver Handle & Installer

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1. Using Driver Handle (special tool #C-4171, Driver Handle, Universal) (1), Drive Handle
Extension (special tool #C-4171-2, Extension, Drive Handle) and Installer (special tool
#10219, Installer, Seal) (2), and install NEW axle shaft seal. Lubricate the inside diameter with
Mopar® Gear and Axle Lubricant to protect seal during halfshaft installation.

2. Install halfshaft. Refer to INSTALLATION .

Fig 2: Rear Axle Drain Plug & Fill Plug

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FLUID FILL

1. Remove fill plug (1) to check and adjust axle fluid level to the bottom of the fill hole. Refer to
CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .

2. Reinstall fill plug and torque to 50 N.m (37 ft. lbs.) torque.

SEAL, DRIVE PINION > REMOVAL > REMOVAL

1. Remove front axle assembly from vehicle. Refer to REMOVAL .

 Fig 1: Measuring Pinion Rotational Torque

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NOTE:

Torque reading must be taken with a constant rotational speed. Do not measure
break away torque.

2. Using a torque wrench (1), measure and record the pinion rotational torque.
 Fig 2: Alignment Mark, Pinion Flange Nut & Pinion Shaft

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NOTE:

Due to axle imbalance concerns, it is necessary to make sure pinion nut-to-shaft

orientation is maintained. If alignment marks are not visible, apply appropriate
marks before removing pinion nut.

3. Apply an alignment mark (2) on the pinion flange nut (1), the pinion shaft (3) and the pinion
flange (4).
 Fig 3: Flange Wrench & Pinion Flange Nut

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4. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1) and 32mm socket, loosen the
pinion flange nut.
 Fig 4: Alignment Mark, Pinion Flange & Shaft

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NOTE:

Due to axle imbalance concerns, it is necessary to make sure pinion flange-to-shaft

orientation is maintained. If alignment marks are not visible, apply appropriate
marks before removing pinion flange.

5. Apply an alignment mark (2) on the pinion flange (1) to the pinion shaft (3) and should be
aligned after nut has been removed.

6. Using Puller (special tool #1026, Puller), remove pinion flange from pinion shaft.
 Fig 5: Seal Remover & Pinion Seal

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7. Using seal remover (special tool #7794-A, Remover, Seal) (1) and slide hammer (special tool
#C-637, Slide Hammer, Universal), remove pinion seal (2) and discard.

SEAL, DRIVE PINION > INSTALLATION > INSTALLATION

Fig 1: Driver Handle & Installer

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1. Clean thread locker from pinion shaft and the pinion nut.

2. Apply light coating of gear lubricant to the outer diameter of the flange on the sealing surface.

3. Using Driver Handle (special tool #C-4171, Driver Handle, Universal) (1) and Installer (special
tool #10220, Installer, Seal) (2), install pinion seal until tool bottoms on carrier.
 Fig 2: Alignment Mark, Pinion Flange & Shaft

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4. Install pinion flange into position. Align index marks between pinion flange and pinion stem to
maintain assembly balance and so that bearing preload is not exceeded.

5. Using Installer (special tool #6448A, Installer, Bearing/Gear), lightly tap on pinion flange until
adequate pinion shaft threads are exposed.
 Fig 3: Flange Wrench & Pinion Flange Nut

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6. Apply Mopar® Lock and Seal Adhesive 2701 to the nut.

7. Install pinion flange nut. Apply axle grease to the pinion nut washer face prior to assembly.
Using Flange Wrench (special tool #C-3281, Holder, Flange) (1) and 32mm socket tighten
pinion flange nut in small increments until the pinion nut index mark aligns with the index
marking on the pinion stem.
Fig 4: Alignment Mark, Pinion Flange Nut & Pinion Shaft

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NOTE:

If pinion nut index mark exceeds the pinion stem index mark the unit must be
discarded. If the pinion nut index mark falls short of the pinion stem index mark the
unit will possibly generate an NVH concern.
 Fig 5: Measuring Pinion Rotational Torque

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NOTE:

Torque reading must be taken with a constant rotational speed. Do not measure
break away torque.

8. Using a torque wrench (1), measure and record the pinion rotational torque.

9. After torque reading has been obtained, compare reading to the recorded reading when
removing the pinion flange. Difference in reading should be within 0 + 0.2 N.m (0 + 1.7 in. lbs.).
Value after repair should be higher due to tighter fit of new seal.

10. Install axle assembly. Refer to INSTALLATION .