instructions for replacing rear pinion seal on 2004 dodge durango.
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2004 Dodge Durango Question: replace pinion seal
Answer #1Bret Bodas September 28, 2009, 21:21Master
Here are the instructions for the 8.25 Inch Axle Pinion Seal Replacement
1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. With vehicle in neutral, position vehicle on hoist.
3. Mark a reference line across the axle flange and propeller shaft flange.
4. Remove propeller shaft.
5. Remove brake calipers and rotors to prevent any drag.
6. Rotate flange three or four times and verify flange rotates smoothly.
7. Measure torque to rotating pinion flange with an inch pound torque wrench. Record reading for installation reference.
8 Install bolts into two of the threaded holes in the flange 180° apart.
9. Position Holder 6719 against the flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so the Holder 6719 is held to the flange.
10 Remove pinion nut and washer.
11. Remove flange with Remover C-452.
12. Remove pinion seal with a pry tool or slide-hammer mounted screw.
# Apply a light coating of gear lubricant on the lip of pinion seal.
# Install new pinion seal with Installer C-4076-B and Handle C-4735.
# Install flange on the end of the shaft with the reference marks aligned.
# Install bolts into two of the threaded holes in the flange 180° apart.
# Position Holder 6719 against flange. Install a bolt and washer into one of the remaining threaded holes. Tighten bolts so Holder 6719 is held to the flange.
# Install flange on pinion shaft with Installer C-3718 and Holder 6719.
# Install pinion washer and a new pinion nut. The convex side of the washer must face outward.
Do not exceed the minimum tightening torque when installing the companion flange retaining nut at this point. Failure to follow these instructions can damage the collapsible spacer or bearings.
# Hold flange with Holder 6719 and tighten pinion nut to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure bearing rollers are seated.
# Rotate pinion flange with an inch pound torque wrench. Rotating torque should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.)
Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions can damage the collapsible spacer or bearings.
# If rotating torque is low use Holder 6719, to hold flange and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved.
The seal replacement is unacceptable if final pinion nut torque is less than 285 Nm (210 ft. lbs.).
The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition.
# Install propeller shaft.
# Install rear brake rotors components.