Installation

INSTALLATION

Special Tools:










1. Install new axle seal(s) (1) if a new seal is required.

NOTE: Always use Seal Protector 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 driveshaft 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 Seal Protector (1). Shift axle assembly in one direction, compressing one halfshaft while installing the other.





4. Verify proper installation by pulling outward on joint (1) by hand.






CAUTION: Differential mounting bolts (1) must be installed through bushings prior to crossmember installation in vehicle. Bolts cannot be inserted through bushings once crossmember is installed.

5. Install differential mounting bolts (1) through crossmember differential mount bushings. Do not tighten at this time.

NOTE: The nut will turn free at the at the top of the axle carrier, it will need to be held with a deep socket during removal.

6. Install rear axle front mount isolator (3) and bolt (1). Do not tighten at this time.





7. Torque differential mounting bolts (1) to 220 Nm (162 ft. lbs.).
8. Torque rear axle front mount isolator bolt (1) to 65 Nm (48 ft. lbs.).





9. Install the front mount bolt cover (1) located at the top of the axle carrier (2).





10. Raise crossmember (1) with jack until crossmember mounting bolts (2) can be installed. Install crossmember mounting bolts.
11. Tighten two rear crossmember mounting bolts (2) to 180 Nm (133 ft. lbs.).





12. Again verify halfshaft inner joints are fully engaged to axle assembly.
13. Remove transmission jack (2).





14. Align propeller shaft index marks (3) and start propeller shaft coupler-to-axle bolt/nuts by hand.





15. Torque propeller shaft coupler-to-axle flange bolt/nuts to proper specifications. [1][2]Drive/Propeller Shaft.





16. Insert wheel speed sensor connectors (3 and 4) into body wiring harness connector (1) located in luggage compartment floor pan (2). When installing connector, make sure retaining clip on body connector is properly in place and sensor connector cannot be pulled out.





17. Install rear exhaust system (2). Installation.





18. Using a 14mm hex, remove rear axle fill plug (1). Check rear axle fluid, adjust as needed with Mopar(R) 75W-140 Synthetic Gear AND Axle Lubricant. Install fill plug and torque to 60 Nm (44 ft. lbs.). .