Half Shaft - Installation

INSTALLATION

NOTE: Halfshaft inner and outer boots are not serviceable separately. Boot replacement requires entire shaft assembly replacement.

CAUTION: Unequal-length halfshafts are used. The left halfshaft is shorter than the right, and it is necessary to identify and tag halfshafts upon removal to ensure proper installation.

CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may cause the boot to pucker or crease, reducing the service life of the boot and joint. Avoid over angulating or stroking the C/V joints when handling the halfshaft.






1. Install new axle seal(s) (1) using Installer 9223 (2).





2. Install halfshaft isolation washer (1). Washer is bi-directional, and can be installed in either direction.






NOTE: Always install a new hub nut. The original hub nut is one-time use only and should be discarded when removed.

3. Install halfshaft (2) to wheel hub/knuckle assembly. Install new hub nut (1) by hand.






NOTE: Inspect slinger(s) for handling damage. Straighten as necessary to avoid contact with axle seal.

NOTE: Use care when installing halfshaft to axle assembly. The halfshaft installation angle should be minimized to avoid damage to seal upon installation.

4. Lubricate halfshaft inner joint bearing journal (3) with Mopar(R) Gear and Axle Lubricant (75W-140). Using new circlip(s), install halfshaft (1) to rear axle assembly. Use care not to damage axle seals (2). Verify proper installation by pulling outward on joint by hand.





5. Raise rear axle assembly into position. Align propeller shaft index marks (3) and start propeller shaft coupler-to-axle bolt/nuts by hand.





6. Install two rear axle-to-crossmember bolts (1) and torque to 220 Nm (162 ft. lbs.).





7. Install rear axle front mount isolator (1) as shown and torque bolt/nut to 65 Nm (48 ft. lbs.).





8. Again verify halfshaft inner joints are fully engaged to axle assembly.
9. Remove transmission jack (1).
10. If used, remove screw-type under-hoist jack stands (2).





11. Torque propeller shaft coupler-to-axle flange bolt/nuts to 58 Nm (43 ft. lbs.).





12. Using a 14mm hex, remove rear axle fill plug (1). Fill axle with Mopar(R) 75W-140 Synthetic Gear AND Axle Lubricant in the following quantities:
- 198 Axle: 1.4L (1.5 qts.)
- 210 Axle: 1.6L (1.7 qts.)

13. Install and torque fill plug (1) to:
- 198 Axle: 60 Nm (44 ft. lbs.)
- 210 Axle: 50 Nm (37 ft. lbs.)





14. V8 Models: Install exhaust system. Tighten band clamps (1) to 61 Nm (45 ft. lbs.).





15. Lower vehicle. Torque halfshaft hub nut (1) to 213 Nm (157 ft. lbs.). Install wheel center cap.





16. Install wheel/tire assembly (1) and torque lug nuts to 150 Nm (110 ft. lbs.).