Output Shaft: Service and Repair

The rear axle assembly must be removed from the vehicle to replace the output shafts. The output shafts are each held in place by a snap ring. Access to these snap rings can only be obtained by removing the rear cover.


REMOVAL
1. Raise vehicle on hoist.
2. Drain differential fluid from differential.
3. Remove rear axle assembly from the vehicle.
4. Remove rear cover.
5. Using a pair of 90 degree angled snap ring pliers, expand the snap ring while pulling outward on the output shaft. The snap ring cannot be removed without pulling on the output shaft.

CAUTION: Tag snap rings as they are being removed. This will ensure that they are reinstalled in the same position that they were in when they were removed.


INSTALLATION

CAUTION: Output shafts are not interchangeable from side to side. One shaft is longer than the other.

1. Install new output shaft.
2. Place the C-clip in position with snap ring pliers. Expand the snap ring while pushing the output shaft back into the differential. Be sure that the snap ring is seated properly in the snap ring groove.
3. Clean rear cover sealing surface. Then apply new sealant and install cover and bolts. Torque bolts to 47 Nm (35 ft. lbs.).
4. Reinstall rear axle into vehicle.

CAUTION: The drive shaft and axle shaft strap bolts incorporate a Loctite patch for retention on initial installation. These screws must be replaced with new pieces or cleaned and Loctite thread locker applied whenever they are removed.

CAUTION: Replace both drive shaft and axle shaft universal joint straps whenever they are removed. The straps slightly deform when torqued in place. Reuse of the straps may result in reduced clamp load on the universal joint cap.

5. The differential capacity is 45 oz. Add one four ounce container of Mopar Limited Slip Additive (MS-5630), then fill the rear axle with Mopar Synthetic Gear & Axle Lubricant 75W-140 (MS-8985).