Front Axle Seal - Leaks on Right Side
NO: 02-12-94GROUP: Front Axle
DATE: Aug. 26, 1994
SUBJECT:
Right Front Axle Seal Leaks
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-03-93 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE ENTIRE REPAIR PROCEDURE HAS BEEN REVISED.
MODELS:
1993 (AN) Dakota
NOTE:
THIS BULLETIN APPLIES ONLY TO 4WD VEHICLES BUILT PRIOR TO APR. 1, 1993 (MDH 4/1/XX).
SYMPTOM/CONDITION:
Some vehicles may exhibit a leak at the right front axle seal.
DIAGNOSIS:
Inspect the right front axle seal area for signs of axle lubricant leakage. If leakage is present, perform the repair procedure.
PARTS REQUIRED:
1 52068535 Right Axle Seal
REPAIR PROCEDURE:
This bulletin involves the installation of an improved design axle seal.
1. Remove the cotter pin, nut lock, and spring washer from the stub shaft.
2. Loosen the lug nuts and hub nut while the vehicle is on the surface with the brakes applied.
3. Raise and support the vehicle
4. Remove the hub nut and washer from the stub shaft. Remove the wheel and tire.
5. Remove the bolts that attach the inner housing flange.
6. Support the drive shaft at the CV joint housings. Separate the stub shaft from the hub bearing. DO NOT PULL ON THE RUBBER BOOT. Remove the CV shaft from the vehicle.
7. Loosen the housing cover bolts and drain the lubricant from the housing. Remove the housing cover.
8. Rotate the differential case so the differential pinion shaft lock screw is accessible. Remove the lock screw and pinion shaft from the differential case.
9. Push the axle shaft C-clip lock from the axle shaft.
10. Remove the axle shaft. Use care to prevent damage to the axle shaft bearing which will remain in the axle shaft tube.
11. Inspect the axle shaft bearing contact surface area for indications of brinelling, spalling, and pitting. If any of these conditions exist, the axle shaft and bearing must be replaced. Wipe the bore in the axle shaft clean.
12. Install bearing into axle shaft tube with installer C-4198 and handle C-4171.
CAUTION:
DO NOT USE THE NEW AXLE SHAFT SEAL TO POSITION OR SEAT THE BEARING IN THE AXLE SHAFT BORE.
13. Install the new seal, P/N 52068535, with installer C-4203 and handle C-4171. The flat side of the installation tool must face the seal.
14. Lubricate the bearing bore and seal lip. Insert the axle shaft and engage the splines with the side gear. Use care to prevent the shaft splines from damaging the axle shaft seal lip.
15. Insert the C-clip lock in the recessed groove. Push the axle shaft outward to seat the C-clip lock.
16. Insert the pinion gear mate shaft in the case. Install through the thrust washers and pinion gears. Align the hole in the shaft with the lock screw hole. Install the lock screw with loctite on the threads. Tighten the screw to 8 ft.lbs. torque.
17. Clean the cover and apply a bead of Mopar Silicone Rubber Sealant around the sealing surface. Allow the sealant to cure for a few minutes.
18. Install the housing cover within 5 minutes after applying the sealant. If not installed, the sealant must be removed and another bead applied.
19. Tighten the cover bolts in a criss cross pattern to 35 ft.lbs. torque.
20. Fill the differential with Mopar Hypoid Gear Lubricant, SAE 80w90, 2.5 pints maximum capacity.
WARNING:
THE FILL LEVEL MUST BE 3/4 INCH BELOW FILL PLUG. FAILURE TO OBSERVE THIS REQUIREMENT CAN RESULT IN COMPLETE DIFFERENTIAL FAILURE.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 02-05-34-91 1.2 Hrs.
FAILURE CODE: P8 - New Part