Dodge 2000 DURANGO Service Manual page 140

3 - 90 8 1/4 AND 9 1/4 AXLE
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 68 Upper Side Gear & Clutch Disc Pack
Installation
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL 8139–2
tighten the forcing screw in order to install the pin-
ion gears.
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw C-4487-2, Step Plate
8139-2, and Threaded Adapter 8139-1.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install the pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
CLEANING AND INSPECTION
8 1/4 AND 9 1/4 AXLES
Wash differential components with cleaning solvent
and dry with compressed air. Do not steam clean
the differential components.
Wash bearings with solvent and towel dry, or dry
with compressed air. DO NOT spin bearings with
compressed air. Cup
replaced as matched sets only.
Clean axle tubes and oil channels in housing.
Inspect for:
and bearing must
• Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces.
• Bearing cups must not be distorted or cracked.
• Machined surfaces should be smooth and with-
out any raised edges.
• Raised metal on shoulders of cup bores should
be removed with a hand stone.
• Wear and damage to pinion mate shaft, differen-
tial pinions, side gears and thrust washers. Replace
as a matched set only.
• Ring gear and pinion for worn and chipped
teeth.
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion
companion
splines, pitted areas, and a rough/corroded seal con-
tact surface. Repair or replace as necessary.
• Pinion depth shims for damage and distortion.
Install new shims if necessary.
• The differential case. Replace the case if cracked
or damaged.
• The axle shaft C-locks for cracks and excessive
wear. Replace them if necessary.
• Each threaded adjuster to determine if it rotates
freely. If an adjuster binds, repair the damaged
threads or replace the adjuster.
• The RWAL exciter ring for damage and missing
teeth. Verify that the ring is fully seated to the dif-
ferential case flange.
Polish each axle shaft sealing surface with No. 600
crocus cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft seal con-
tact surface. When polishing, the crocus cloth should
be moved around the circumference of the shaft (not
in-line with the shaft).
TRAC-LOK
Clean all components in cleaning solvent. Dry com-
ponents with compressed air. Inspect clutch pack
plates for wear, scoring or damage. Replace both
clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
Inspect differential case and pinion shaft. Replace if
worn or damaged.
PRESOAK PLATES AND DISC
Plates and discs with fiber coating (no grooves or
lines) must be presoaked in Friction Modifier before
assembly. Soak plates and discs for a minimum of 20
minutes.
be
flange for cracks,
DN
worn