September 2013 Dealer Service Instructions for: Safety ...

Copyright 2013, Chrysler Group LLC, All Rights Reserved

September 2013Dealer Service Instructions for:

Safety Recall N08Rear Axle Pinion Nut

NOTE: Vehicles that are involved in Safety Recall M34 are not included in thisrecall.

2009 - 2012 (DS) RAM Truck (1500 series)

(ND) Dodge Dakota

2009 (HB) Dodge Durango

(HG) Chrysler Aspen

NOTE: This recall applies only to the above vehicles equipped with a 9.25 rearaxle (sales code DRB) or a C235 rear axle (sales code DRN).

The rear axle pinion nut on about 63 315 of the above vehicles may loosen due toundersized pinion shaft splines. A loose pinion nut could cause the rear axle toseize or cause the driveshaft to separate resulting in a loss of motive power. Eithersituation could cause a crash without warning.

Models

IMPORTANT: Some of the involved vehicles may be in dealer used vehicleinventory. Dealers should complete this recall service on these vehicles beforeretail delivery. Dealers should also perform this recall on vehicles in for service.Involved vehicles can be determined by using the VIP inquiry process.

Subject

Safety Recall N08

The rear axle pinion nut must be inspected. Rear axles found with a loose pinionnut and/or a seized up rear axle assembly must be reconditioned. Rear axles with a6-point pinion nut that has not loosened will have a pinion nut retainer installed.All rear axles with a 12-point pinion nut require no additional repairs.

Part Number Description

CBHKM342AA Rear Axle Retainer Package (All Axles)

Each package contains the following components:

Quantity Description

1 Retainer, Pinion Nut

4 Bolt, Propeller Shaft-to-Companion Flange

2 Bit, Hex (3/32”)

Each dealer to whom vehicles in the recall were assigned will receive enoughRear Axle Retaining Packages to service about 20% of those vehicles.


06506497AA Propeller Shaft-to-Companion Flange Bolt(Four Bolts Required on All Axles) (MSQ is 4)

Repair

Parts Information

Safety Recall N08

Rear Axle Packages for 9.25 Axles (sales code DRB)


CBAKM343AA Rear Axle Package (sales code DMH / 3.92 ratio)

CBAKM344AA Rear Axle Package (sales code DMD / 3.55ratio)

CBAKM345AA Rear Axle Package (sales code DMC / 3.21ratio)

CBAKM346AA Rear Axle Package (sales code DMF / 4.10 ratio)



1 Gear, Ring

1 Gear, Pinion

1 Seal, Pinion

1 Nut, Pinion

1 Sleeve, Crush

1 Bearing, Pinion Front

1 Bearing, Pinion Rear

12 Bolts, Ring Gear

Parts Information (Continued)

Safety Recall N08

Rear Axle Packages for C235 Axles (sales code DRN)

SPECIAL NOTE: If the ring and pinion on a C235 axle is being replaced thedifferential case assembly must also be ordered. The new ring and pinion isnot compatible with the original differential case assembly.


CBL2N081AA Rear Axle Package (sales code DMH / 3.92 ratio)

CBL2N082AA Rear Axle Package (sales code DMF / 4.10 ratio)

CBL2N083AA Rear Axle Package (sales code DMD / 3.55 ratio)

CBL2N084AA Rear Axle Package (sales code DMC / 3.21 ratio)



1 Gear, Ring

1 Gear, Pinion

1 Nut, Pinion

1 Sleeve, Crush

1 Bearing, Pinion Front

1 Bearing, Pinion Rear

12 Bolts, Ring Gear

1 Flange, Companion

CBL2N087AA Case Assembly, Differential (C235 axle withoutTrac-Lok) (sales code DS8) NOTE: Includesside gears

CBL2N086AA Case Assembly, Differential (C235 axle withTrac-Lok) (sales code DSA) NOTE: Includes sidegears


Safety Recall N08

Pinion Depth Shim Kits


CBAKM347AA Pinion Depth Shim Kit (9.25 axle / sales code DRB)

CBL2N085AA Pinion Depth Shim Kit (C235 axle / sales code DRN)

For 9.25 Axles: (If the original ring and pinion is being reused,order the parts below)

CBAKM348AA Seal, Pinion

CBAKM349AA Nut, Pinion

03507678 Sleeve, Crush

05072498AA Bearing, Pinion Front (bearing and cup)

05017438AA Bearing, Pinion Rear (bearing and cup)

05072506AA Bearings, Differential Carrier Side(contains two bearings and two cups)

For C235 Axles: (If the original ring and pinion is being reused,order the parts below)

CBAKM348AA Seal, Pinion

CBAKM349AA Nut, Pinion

03507678 Sleeve, Crush

68067932AB Bearing, Pinion Front (bearing and cup)

68067931AC Bearing, Pinion Rear (bearing and cup)

CBL2N088AA Bearings, Differential Carrier Side(contains two bearings and two cups)


Safety Recall N08

For 9.25 Axles:

68045427AA Shaft, Axle (without ABS tone wheel)

52114720AB Shaft, Axle (with ABS tone wheel)

52111197AB Bearing, Axle Shaft

52111198AB Seal, Axle Shaft

04798912AD Side Gear Kit (without Trac-Lok)

05161549AA Case Assembly (with Trac-Lok) (sales code DSA)

For C235 Axles:

68065488AA Shaft, Axle (right side)

68065489AA Shaft, Axle (left side)

52111197AB Bearing, Axle Shaft

52111198AB Seal, Axle Shaft

68067898AC Side Gear Kit (without Trac-Lok)

All Axles:

0VU01299 (Can) Lube, Rear Axle (SAE 75W-140)

04874469 (USA) Lube, Rear Axle (SAE 75W-140)

04318060AB Additive, Limited Slip

05013477AA Axle-RTV

04318031 Adhesive, Lock & Seal (medium strength threadlocker)

04883065 Compound, Gear Marking

05012249AB Lubricant, Nickel Anti-Seize(NOTE: One bottle of nickel anti-seize canrepair 20 vehicles)


Safety Recall N08

The following special tools are required to perform this repair:

6719A Holder, Position

C-4164 Adjuster Wrench

C-293-PA Puller

C-293-47 Puller

C-293-3 Adapter

C-452 Puller

C-10258 Remover

C-4171 Handle

C-4309A Remover

C-4310 Installer

D-129 Installer

6739 Pinion Height Block

8542 Pinion Block

6741 Screw

6740 Cone Nut

8541A Arbor Discs

D-115-3 Arbor

C-3339A Dial Indicator

D-115-2A Scooter Block

C-4076-B Installer

C-4735 Handle

C-3095-A Installer

C-3718 Installer

C-4213 Installer, bearing

6310 Bearing Remover

6310-9 Foot

C-4198 Installer

C-4076-B Installer

Special Tools

Safety Recall N08

A. Inspect Rear Axle Pinion Nut

1. If the rear axle has locked up and/orhas completely failed, continue toSection B. Recondition RearAxle. If the axle seems to befunctioning properly, continue withStep 2 of this inspection procedure.

2. Lift the vehicle on an appropriatehoist.

3. Mark the propellershaft-to-companion flange tomaintain orientation duringinstallation of the propeller shaft(Figure 1).

4. Remove and discard the four rear propeller shaft retaining bolts.

5. Separate the propeller shaft from the companion flange and set the end of thepropeller shaft onto a jack stand.

CAUTION: Do not allow the propeller shaft to hang from thetransmission/transfer case unsupported.

6. If the rear axle is equipped with a:

12 point pinion nut, the rear axlerequires no repair (Figure 2).Using new bolts, install thepropeller shaft to the companionflange. Tighten the bolts to85 ft. lbs. (115 N·m). Return thevehicle to the customer.

6 point pinion nut, continue withStep 7 of this procedure.

Service Procedure

Figure 1 – Mark Propeller Shaft-to-CompanionFlange Orientation

COMPANIONFLANGE

PROPELLERSHAFT

Figure 2 – 12 Point Pinion Nut

12 POINTPINION NUT

PINION SHAFT

COMPANION FLANGE

Safety Recall N08

7. Place a mark on the pinion nut andpinion shaft as shown in Figure 3.

8. Place the Position Holder 6719Aagainst the companion flange andinstall a bolt and washer in thethreaded holes (Figure 4). Tightenthe bolts so the Position Holder6719A is held to the flange.

Service Procedure (Continued)

Figure 3 – Mark Pinion Nut and Pinion Shaft

Figure 4 – Install Position Holder 6719A

PINIONSHAFT

6 POINTPINION NUT

MARKSCOMPANION

FLANGE

POSITIONHOLDER

6719A

COMPANIONFLANGE

PINIONNUT

Safety Recall N08

9. Using a torque wrench, tighten the pinion nut to 50 ft. lbs. (68 N·m) (Figure 5).


Figure 5 - Attempt to Tighten Pinion Nut

TORQUEWRENCH

COMPANIONFLANGE

SOCKET

POSITION HOLDER6719A

Safety Recall N08

10. Inspect the mark placed on the pinion nut and pinion shaft:

If the pinion nut mark has not moved (Figure 6), continue with Step 11 ofthis procedure.

If the pinion nut mark has moved (Figure 6), the ring and pinion must bereplaced. Continue with Section B. Recondition Rear Axle.

11. Using a torque wrench, tighten the pinion nut to 100 ft. lbs. (135 N·m) (Figure 5).

12. Again, inspect the mark placed on the pinion nut and pinion shaft:

If the pinion nut mark has not moved (Figure 6), continue with Section C.Install Pinion Nut Retainer Ring.

If the pinion nut mark has moved (Figure 6), the ring and pinion must beinspected and/or replaced if necessary. Continue with Section B.Recondition Rear Axle.


Figure 6 – Inspect for Pinion Nut Movement on the Pinion Shaft

PINION NUT MARK HAS NOT MOVED PINION NUT MARK HAS MOVED

MARKS STILLALIGNED

MARKS NOTALIGNED

PINIONNUT

PINIONSHAFT

PINIONNUT

PINIONSHAFT

Safety Recall N08

B. Recondition Rear Axle

NOTE: Only rear axles with a loose pinion nut and/or a complete axle failure,as determined by the inspection in Section A, require reconditioning. Veryfew vehicles are expected to require rear axle reconditioning.

SPECIAL NOTE: There are two different type of rear axles involved in thisrecall, the 9.25 Chrysler rear axle and the C235 rear axle. The reconditionprocedure varies slightly between the two rear axles. The easiest way todetermine which rear axle the vehicle has is to look for a drain plug on therear axle housing (Figure 7).

A rear axle without a steel drain plug in the rear axle housing is a 9.25rear axle.

A rear axle with a steel drain plug in the rear axle housing is a C235rear axle.

1. Lift the vehicle on an appropriate hoist.


Figure 7 – Rear Axle Identification

STEEL DRAINPLUGDIFFERENTIAL

COVER

RUBBER FILLPLUG

Safety Recall N08

2. For vehicles with a rear stabilizer bar, remove and save the four stabilizer barmounting bolts on the left and right rear axle brackets, swing the stabilizer barup and secure with straps (Figure 8).

3. Remove and save the differential cover (Figure 8).

4. Remove and save both rear tire and wheel assemblies.


Figure 8 – Relocate Stabilizer Bar for Access to Rear Axle

LEFT AXLEBRACKET

RIGHT AXLEBRACKET

STABILIZER BARBAR

STRAP

STRAP

Safety Recall N08

5. Remove both axle shafts using thefollowing procedure:

a. Remove and save the brakecalipers, adapters, and rotors.

b. Rotate the differential case sopinion mate shaft lock screw isaccessible (Figure 9).

c. Remove and save the lock screwand pinion mate shaft from thedifferential case (Figure 9).

d. Push the axle shafts inward andremove C-locks from the axleshafts (Figure 10).

e. Carefully remove the axle shaftsto prevent damage to the axleshaft bearing and axle shaft sealin the axle tube.


Figure 9 – Remove Lock Screw and PinionMate Shaft

Figure 10 – Axle Shaft C-Locks

DIFFERENTIALCASE

PINION MATESHAFT

LOCKSCREW

AXLE SHAFTC-LOCK GROOVES

C-LOCK

Safety Recall N08

6. For axles that were locked up, inspect the axle shaft splines and bearing racefor damage.

If the axle shaft(s) splines are not twisted or broken and/or the bearing raceon the axle shaft is not pitted or gouged, continue with Step 8 of thisprocedure.

If the axle shaft(s) splines are twisted or broken and/or the bearing race onthe axle shaft is pitted or gouged, continue with Step 7 of this procedure.

7. For axles that were locked up and have damaged axle shaft splines orbearing race, use the following procedure to replace the axle shaft bearing(s).

NOTE: Only rear axles with a complete axle failure (locked up), mayrequire axle shaft and axle shaft bearing replacement. Very few vehiclesare expected to require axle shaft replacement.

a. Remove and discard axle shaft bearing(s) with Bearing Remover 6310 andFoot 6310-9.

b. Install the axle shaft bearing with Installer C-4198 and Handle C-4171 .Drive bearing in until the tool contacts the axle tube.

CAUTION: The axle shaft bearing is installed into the axle tube with thebearing part number against the installer.

c. Coat the lip of the new axle seal with axle lubricant and install with InstallerC-4076-B and Handle C-4735.

d. Continue with Step 8 of this procedure.

8. Mark the differential housing and the bearing caps for installation reference.


Safety Recall N08

9. Remove the bearing threadedadjuster lock from each bearingcap (Figure 11).

10. Loosen the differential bearing capbolts (Figure 11).

11. Insert Adjuster Wrench C-4164into the end of the axle tube andloosen both of the differentialbearing adjusters.

12. Hold the differential case whileremoving the bearing caps andadjusters.

13. Remove and save the differential case from the axle housing (Figure 12).

14. For C235 axles: if the ring and pinion is being replaced, discard the differentialcase and ring gear (Figure 12).

NOTE: The new ring and pinionfor the C235 axle requires thatthe differential case be replaced(Figure 12). The differentialcase can only be reused if thering and pinion is not beingreplaced.

15. For 9.25 axles: if the ring andpinion requires replacement,remove and discard the ring gearattaching bolts. Then drive thering gear off the differential casewith a soft hammer. Discard theoriginal ring gear.

NOTE: The ring gear bolts haveleft-handed threads.


Figure 11 – Adjuster Locks and Bearing Caps

Figure 12 – Differential Case

ADJUSTERLOCK

BEARINGCAP

ADJUSTERLOCK

BEARINGCAP

RINGGEAR

DIFFERENTIALCASE

DIFFERENTIALBEARING AND

CUP

Safety Recall N08

16. Remove the pinion from thedifferential case using thefollowing procedure:

a. Place the Position Holder6719A against the companionflange and install a bolt andwasher into the threaded holes(Figure 13). Tighten the boltsso the Position Holder 6719A isheld to the flange.

b. Use Position Holder 6719A to hold the companion flange and remove thepinion nut (Figure 13).

c. Remove the Position Holder 6719A from the companion flange.

d. Remove the companion flangewith Puller C-452 (Figure 14).

NOTE: On C235 axles if thering and pinion is beingreplaced the companion flangemust also be replaced. Do notreuse the original companionflange if the ring and pinion isbeing replaced.


Figure 13 – Pinion Nut

Figure 14 – Companion Flange Puller C-452

IMPACT WRENCHAND SOCKET

POSITIONHOLDER

6719A

COMPANIONFLANGE

PULLERC-452

Safety Recall N08

e. While holding the pinion gearfrom the differential housingopening, hit the end of the pinionshaft with a soft hammer toremove (Figure 15).

f. Remove and discard the pinion oil seal using a pry tool (Figure 16).

g. Remove the front pinion bearingand the oil slinger, if equipped.


Figure 15 – Pinion Gear Removal

Figure 16 – Pinion Oil Seal Removal

PINIONSHAFT

OIL SEALREMOVAL TOOL

PINIONOIL SEAL

Safety Recall N08

h. Remove the front pinion bearingcup with Remover C-10258,Handle C-4171 and a hammer(Figure 17).

i. Remove the rear pinion bearingcup from the housing withRemover C-4309A, HandleC-4171 and a hammer (Figure 18).

NOTE: Remover C-4309A mustbe placed into position in thedifferential case before attachingthe C-4171 handle.


Figure 17 – Front Pinion Bearing Cup Removal

Figure 18 – Rear Pinion Bearing Cup Removal

REMOVERC-10258

HANDLEC-4171

REAR PINIONBEARING CUP

REMOVERC-4309A

HANDLEC-4171

Safety Recall N08

17. Clean the housing cavity withflushing oil, light engine oil and/ora lint free cloth.

CAUTION: Do not use steam,kerosene or gasoline to clean thedifferential housing.

18. Install the rear pinion bearing cupwith Installer C-4310, HandleC-4171 and a hammer (Figure 19).

NOTE: Be sure that the rearpinion bearing cup is fully seatedin the differential case.

19. Install the front pinion bearing cupwith Installer D-129, HandleC-4171 and a hammer (Figure 20).

NOTE: Be sure that the frontpinion bearing cup is fully seatedin the differential case.

CAUTION: Failure to seat boththe front and/or rear pinionbearing cups completely in thedifferential case will cause thepinion bearing preload todecrease after the axle has beenput into service. Low pinionbearing preload will cause axlefailure.


Figure 19 – Rear Pinion Bearing CupInstallation

Figure 20 – Front Pinion Bearing CupInstallation

INSTALLERC-4310

HANDLEC-4171

INSTALLERD-129

HANDLEC-4171

HAMMER

Safety Recall N08

20. Use the following procedure to setpinion depth:

a. Assemble the Pinion Height Block6739, Pinion Block 8542 and newrear pinion bearing onto Screw6741 (Figure 20).

b. Insert the Pinion Block 8542,Pinion Height Block 6739, newrear bearing, and Screw 6741 intothe housing through pinion thebearing cups (Figure 21 and 22).

NOTE: Do not lubricate the front or rear pinion bearing with gearlubricant before installing. All turning torque specifications arecalculated with dry bearings.

c. Install new front pinion bearing and Cone 6740 and nut onto the Screw 6741).Tighten the cone-nut until the turning torque of the screw is 22 in. lbs. (2.5 N·m)(Figure 21 and 22).


Figure 22 – Pinion Depth Tool Installation

Figure 21 – Check Turning Torque

CONE 6740

SCREW6741

NUT

NEW FRONTPINION BEARING

SCREW6741

CONE6740

NUT

PINIONHEIGHT

BLOCK 6739

NEW REARPINION

BEARING

PINIONBLOCK 8542

Safety Recall N08

d. Place the Arbor Discs 8541A on Arbor D-115-3 in position in the housingside bearing cradles. Install the differential bearing caps on the arbor discsand tighten the bearing cap bolts to 80 ft. lbs. (108 N·m) (Figure 23).

NOTE: Follow the printed instructions on the arbor discs for properorientation and installation of the discs.


Figure 23 – Arbor Discs 8541A and Arbor D-115-3

ARBOR DISCS8541A

ARBORD-115-3

BEARINGCAP BOLTS

BEARINGCAP BOLTS

Safety Recall N08

e. Assemble the Dial Indicator C-3339A into Scooter Block D-115-2A andsecure the set screw (Figure 24).

f. Place the Scooter Block/Dial Indicator in position in axle housing so the DialIndicator probe and the Scooter Block are flush against the rearward surfaceof the Pinion Height Block (Figure 24). While holding the Scooter Block inplace and zero the Dial Indicator. Tighten the Dial Indicator face lock screw.


Figure 24 – Zeroing the Dial Indicator

DIAL INDICATORPROBE

SCOOTERBLOCK

(D-115-2A)

PINION HEIGHTBLOCK (6739)

DIAL INDICATORPROBE AND

SCOOTER BLOCKFLUSH AGAINSTPINION HEIGHT

BLOCK

ZERO THE DIALINDICATOR(C-3339A)

DIAL INDICATORFACE LOCK

SCREW

Safety Recall N08

g. Slide the Dial Indicator probe across the gap between the Pinion HeightBlock and the Arbor Bar with the Scooter Block against the Pinion HeightBlock (Figure 25). Continue moving the dial probe to the crest of the ArborBar and record the highest reading obtained on the Dial Indicator.


Figure 25 – Measure pinion Depth Requirement

DIAL INDICATORPROBE ON HIGHEST

POINT ON THE ARBORBAR

SCOOTER BLOCKFLUSH AGAINST THE

PINION HEIGHT BLOCK

Safety Recall N08

h. For 9.25 axles, select a shim equal to the Dial Indicator reading plus orminus the pinion depth variance number marked on the pinion gear. Forexample:

If the depth variance is -3, add 0.003 in. to the Dial Indicator reading.

If the depth variance is +3, subtract 0.003 in. from the Dial Indicatorreading.

NOTE: Some pinion gears will be marked on the end of the pinion gearhead and some will be marked with a paint pencil on the pinion shaft(Figure 26).

i. For 9.25 axles, subtract two thousands (0.002) from the shim thickness thatwas determined in the previous step to compensate for pinion bearing growth.

NOTE: Bearing growth occurs when the bearing is pressed onto thepinion shaft.


Figure 26 – Pinion Depth Variance Markings (9 ¼ axles)

PINION DEPTHVARIANCE NUMBER

PINION DEPTHVARIANCE NUMBER

Pinion Shown is a +2 Pinion Shown is a Zero

Safety Recall N08

For C235 Axles Only:

NOTE: C235 axle ring gear and pinion gears are supplied as matched set.Identifying numbers for the ring gear and pinion are laser etched onto thepinion gear shaft and the side of the ring gear (Figure 27). The first number isthe gear set sequence number and will be the same for the pinion and ringgear. The second line has a plus (+) followed by a variance number. Thethird line is the last six digits of the part number.

Compensation for pinion gear depth variance is achieved with select shims.The shims are placed behind the rear pinion bearing cup.

Calculating the pinion depth variance will require some simple math.Subtract the number etched in the pinion from the standard pinion depth of117.475 in millimeters.

Example 1: New pinion has a marking of 117.485. Subtract 117.485 from117.475. (117.475 - 117.485 = negative (-) 0.010 mm).

Example 2: New pinion has amarking of 117.465. Subtract 117.465from 117.475 (117.475 - 117.465 =positive (+) 0.010 mm).

Example 3: New pinion has amarking of 117.475. Subtract 117.475from 117.475 (117.475 - 117.475 =0.00 mm).

This will indicate a positive (+) ornegative (-) number and will be addedor subtracted from the calculated shimthickness later in the procedure.Record the calculated pinion depthvariance, positive (+) or negative (-),for later use.


PINION GEAR

PINIONSHAFT

LASER ETCHEDIDENTIFYING

NUMBERS

Figure 27 – Laser Etched IdentificationNumbers

Safety Recall N08

j. For C235 Axles only, select a shim equal to the dial indicator reading plus orminus the pinion depth variance calculated earlier, then subtract 0.072 mm(0.003 in.) from the overall calculations.

If the calculated pinion depth variance recorded earlier is positive (+), addthe calculated number from the dial indicator reading.

If the calculated pinion depth variance recorded earlier is negative (-),subtract the calculated number to the dial indicator reading

NOTE: Shim Thickness Formula = Dial indicator reading plus (+) thepinion depth variance minus (-) the bearing growth factor.

Example 1: Shim thickness = 1.90 mm (dial indicator reading) plus (+)+ 0.010 mm (a positive pinion depth variance) minus (-) 0.072 mm(bearing growth factor) = 1.838 mm.

Example 2: Shim thickness = 1.90 mm (dial indicator reading) plus (+)- 0.010 mm (a negative pinion depth variance) minus (-) 0.072 mm(bearing growth factor) = 1.818 mm.

k. For C235 axles only, remove the rear pinion bearing cup from the differentialhousing and install the selected shim (thickness as close as possible to thecalculated number) behind the rear pinion bearing cup.


Safety Recall N08

21. Install the new front pinion bearing,and oil slinger if equipped, into thedifferential case.

22. Apply a light coating of gear lubricanton the lip of the new pinion oil seal.Install the pinion seal with InstallerC-4076-B, Handle C-4735 and ahammer (Figure 28).

23. If the ring and pinion is being reused,remove and discard the rear pinionbearing from the pinion shaft.

24. For 9.25 axles only, install the piniondepth shim selected in Step 20i. on thepinion gear shaft (Figure 29).

NOTE: The C235 axle has thepinion depth shim located behindthe rear pinion bearing cup.

25. Using a hydraulic press, install thenew rear pinion bearing on the pinionshaft with Installer C-3095-A(Figure 29).


Figure 28 – Install Pinion Seal

Figure 29 – Press Rear Pinion Bearingonto Pinion Shaft

HAMMER HANDLEC-4735

INSTALLERC-4076-B

PINIONGEAR

PINIONDEPTHSHIM

REAR PINIONBEARING

INSTALLERC-3095-A

Safety Recall N08

26. Install a new crush sleeve on thepinion shaft (Figure 30).

27. Install the pinion gear into thedifferential case.

28. Install the companion flange withInstaller C-3718 and Position Holder6719A (Figure 31).

CAUTION: For C235 axles, if thering and pinion was replaced, thecompanion flange must also bereplaced. The new ring and pinionis not compatible with the originalcompanion flange.


Figure 30 – Install New Crush Sleeve

Figure 31 – Companion Flange InstallerC-3718

CRUSHSLEEVE

PINIONSHAFT

INSTALLERC-3718

COMPANIONFLANGE

Safety Recall N08

29. Install a new pinion nut onto thepinion shaft (Figure 32).

30. Hold the companion flange withPosition Holder 6719A and tightenthe pinion nut, with a high qualityimpact wrench, until there is nofree-play in the bearings(Figure 33).

31. Remove the Position Holder6719A from the companion flange.

32. Rotate the companionflange/pinion several times to seatthe pinion bearings.


Figure 32 – Install New Pinion Nut

Figure 33 – Tighten Pinion Nut until there is no Free-play in the Pinion Bearings

PINIONNUT

POSITIONHOLDER 6719A

PINION SHAFT

PLACE A LINE ON THESOCKET TO HELP MONITOR

THE AMOUNT THE PINIONNUT IS ROTATING

HIGH TORQUEIMPACT WRENCH

HIGH QUALITYIMPACT GRADE

DEEP WELL SOCKET

Safety Recall N08

33. Measure the pinion turning torque with a “dial type” inch pound torque wrench.The correct pinion turning torque range is 15 - 35 in. lbs. (1.7 - 4.0 N·m).The preferred setting is 25 in. lbs. (2.8 N·m).

If the pinion turning torque is too low, install the Position Holder6719A and tighten the pinion nut in small increments. Then removethe Position Holder, rotate the flange several times and recheck thepinion turning torque. Repeat, if necessary, in small incrementsuntil the correct pinion turning torque is achieved (Figure 34).

If the pinion turning torque is too high, never loosen the pinion nutto decrease pinion bearing turning torque. If the pinion turningtorque is exceeded a new crush sleeve must be installed.

NOTE: Placing a line on the side of the socket will help to determine howmuch the socket turned while tightening the pinion nut in small increments(Figure 33).


Figure 34 – Check Turning Torque with Dial Type Inch Pound Torque Wrench

DIAL TYPE INCH POUNDTORQUE WRENCH

Safety Recall N08

34. For C235 axles: Using a 3/16 in. flat punch and hammer, crimp the pinion nutto the pinion shaft. The crimp must align with the grooves in the pinion shaft(Figure 35).

CAUTION: Be sure to crimp both sides of the pinion nut.


Figure 35 – Crimp 12 Point Pinion Nut

HAMMER3/16” FLATPUNCH

CRIMP BOTH SIDESOF THE 12 POINT

PINION NUT

COMPANIONFLANGE

Safety Recall N08

35. Inspect, and replace if required, thedifferential side bearings. UsePuller/Press C-293-PA, BlockSet/Puller C-293-47 andAdapter/Bearing/Gear C-293-3(Figure 36).

NOTE: For vehicles with aTrac-Lok unit, if damaged axleshaft splines were found, replacethe Trac-Lok unit.

36. Position the ring gear on the differential case and start two new ring gear bolts.This will provide case-to-ring gear bolt hole alignment.

37. Secure the differential case in asoft-jawed vise.

38. Install the new ring gear bolts andalternately tighten to 115 ft. lbs.(156 N·m) (Figure 37).

CAUTION: Never reuse theoriginal ring gear bolts.


Figure 36 – Differential Side Bearing Removal

Figure 37 – Tighten Ring Gear Bolts

PRESSC-293-PA

SOFT JAWVISE

RING GEARBOLTS

RINGGEAR

TORQUEWRENCH

Safety Recall N08

39. If replaced, install the differential sidebearings with Bearing InstallerC-4213, Handle C-4171 and a hammer(Figure 38).

40. Place the differential case/ring gearassembly into the differential housing.

41. Install the bearing caps and bolts.Lightly snug the bearing cap retainingbolts.

CAUTION: Ensure that thedifferential bearing caps areinstalled on the correct side byverifying the markings made inStep 8.

42. Turn each thread adjuster inward withAdjuster Wrench C-4164 until the differential bearing end-play is eliminatedand the ring gear backlash is approximately 0.001 in. (0.025 mm). Seat thebearing cups by rapidly rotating the ring gear a half turn back and forth severaltimes.

43. Install a Dial Indicator (C-3339) withprobe positioned against a ring geartooth (Figure 39). Measure andrecord backlash at 4 positions, 90degrees apart around the ring gear.Mark the lowest backlash position onthe ring gear and make all backlashmeasurements at this location.


Figure 38 – Install Differential Side Bearings

Figure 39 – Measure Backlash in 4 Positions

BEARINGINSTALLER C-4213

HANDLE C-4171

DIFFERENTIALSIDE BEARING

DIALINDICATOR

PROBE

SOFTJAWS

Safety Recall N08

44. Loosen the left-side threaded adjuster and tighten the right-side threaded adjusterevenly with Adjuster Wrench C-4164 to obtain a backlash of 0.003 - 0.004 in.(0.076 - 0.102 mm).

45. Tighten both adjusters to 10 ft. lbs. (14 N·m). Seat the differential bearing cupsby rapidly rotating the ring gear a half turn back and forth several times.

46. Tighten the differential bearing cap bolts 100 ft. lbs. (136 N·m).

47. Tighten the right-side threaded adjuster to 75 ft. lbs. (102 N·m). Seat thedifferential bearing cups by rapidly rotating the pinion gear a half turn back andforth several times. Continue this procedure until right-side adjuster torqueremains a constant 75 ft. lbs. (102 N·m).

48. Measure the ring gear backlash. Ring gear-to-pinion gear backlash should be0.005 - 0.008 in. (0.12 - 0.20 mm).

If backlash is less than 0.005 in. (0.12 mm) increase the torque on theright-side threaded adjuster until the specified ring gear-to-pinion backlash isobtained.

If backlash is more than 0.008 (0.20 mm) repeat procedure from thebeginning (Step 41).

49. Tighten the left-side threaded adjuster to 75 ft. lbs. (102 N·m). Seat thedifferential bearing cups by rapidly rotating the pinion gear a half turn back andforth several times. Continue this procedure until left-side adjuster torqueremains a constant 75 ft. lbs.(102 N·m).

50. Install the threaded adjuster locksand tighten the lock screws to90 in. lbs. (10 N·m) (Figure 40).

51. Measure the backlash at 4 positionsaround the ring gear, 90 degreesapart. The maximum ring gearbacklash variation is 0.003 in.(0.076 mm).


Figure 40 – Tighten Lock Screws

ADJUSTER LOCKSCREWS

TORQUEWRENCH

Safety Recall N08

52. Use the following procedure to perform a gear pattern check:

a. Wipe clean each tooth of the ring gear.

b. Apply Mopar gear marking compound to all of the ring gear teeth(Figure 41).

c. Create an additional 10 ft. lbs. (14 N·m) pinion rotating torque.

d. Rotate the pinion yoke four (4) full revolutions in each direction.


Figure 41 – Apply Gear Marking Compound to Ring Gear Teeth

GEAR MARKINGCOMPOUND ON ALL RING

GEAR TEETH

Safety Recall N08

e. Read gear tooth contact pattern.

The gear contact pattern iscorrect. Backlash and piniondepth is correct (Figure 42).

The ring gear is too far awayfrom the pinion gear, coastside toe (1) and drive sideheel (2). Decrease thebacklash, by moving the ringcloser to the pinion gearusing the adjusters(Figure 43).


Figure 42

Figure 43

Safety Recall N08

The ring gear is too close tothe pinion gear, drive side toe(1) and coast side heel (2).Increase backlash, by movingthe ring away from the piniongear using the adjusters(Figure 44).

The ring gear is too far awayfrom the pinion gear, driveside heel (1) and coast sideheel (2). Decrease thebacklash, by moving the ringcloser to the pinion gear usingthe adjusters (Figure 45).

The ring gear is too close topinion gear, drive side toe (1)and coast side toe (2). Increasethe backlash, by moving thering away from the pinion gearusing the adjusters (Figure 46).


Figure 44

Figure 45

Figure 46

Safety Recall N08

The pinion gear is set too low.Increase the pinion gearheight, by increasing thepinion depth shim thickness(Figure 47).

The pinion gear is set toohigh. Decrease the piniondepth, by decreasing thepinion depth shim thickness(Figure 48).


Figure 47

Figure 48

Safety Recall N08

53. For axles that were locked up,inspect for damaged splines insidethe side gears. Replace the sidegears if required.

NOTE: If the axle shaft(s) wereinspected and one or both werefound to be damaged, vehicleswithout Trac-Lok must have theside gears replaced.

NOTE: If the axle shaft(s) wereinspected and one or both werefound to be damaged, vehicleswith Trac-Lok must have theTrac-Lok unit replaced.

54. For vehicles without Trac-Lok, lubricate the side gears and thrust washerswith axle lube before installing them into the differential case (Figure 49).

55. For vehicles without Trac-Lok, install the differential side gears into thedifferential case housing.


Figure 49 – Lubricate Side Gears and ThrustWashers

SIDE GEARSTHRUSTWASHER

Safety Recall N08

56. Install the right and left side axleshafts using the following procedure:

a. Lubricate the bearing bore andseal lip with gear lubricant.

b. Install the axle shafts and engageinto side gear splines.

CAUTION: Use care wheninstalling the axle shafts toprevent the shaft splines fromdamaging axle shaft seal.

c. Insert the C-lock in the end of theaxle shafts, then pull the axleshafts outward to seat the C-lock inthe side gears (Figure 10).

d. Insert the pinion shaft into the differential case and through the thrustwashers and differential pinions (Figure 50).

e. Align the hole in pinion mate shaft with hole in the differential case andinstall the lock screw with Mopar threadlocker (P/N 04318031) on thethreads. Tighten the lock screw to 8 ft. lbs. (11 N·m) (Figure 46).

57. Install the differential cover using the following procedure:

a. Clean the differential housing-to-differential cover sealing surface.

b. Clean the differential cover.

c. Apply a ¼ in. (6.35mm) bead of Mopar Axle RTV to the differential cover.

CAUTION: If the differential cover is not installed within 3 to 5minutes, the differential cover must be cleaned and new RTV applied.Failure to follow these instructions will result in a gear lubricant leak.

d. Install the differential cover. Tighten the differential cover bolts in acrisscross pattern to 30 ft. lbs. (41 N·m).


Figure 50 – Pinion Mate Shaft Lock Screw

PINION MATESHAFT

PINION MATE SHAFTLOCK SCREW

Safety Recall N08

58. For trucks with the original axleshaft(s), using a piece of emerycloth, remove all corrosion from theaxle shaft hubs (Figure 51).

59. Apply a light coat of Mopar NickelAnti-Seize Lubricant to both axleshaft hubs (Figure 52).

60. Install the brake rotors, caliperadapters and calipers. Tighten thecaliper adapter bolts to 120 ft. lbs.(163 N·m).

61. For vehicles equipped with aTrac-Lok differential, install onebottle of Mopar limited slip additive (Friction Modifier) into the differential.

62. Fill the differential with Mopar SAE 75W-140 Synthetic Gear & AxleLubricant to the bottom of the fillhole in the differential cover.

63. Install the rear axle lubricant rubberfill plug into the differential cover.

64. For vehicles with a rear stabilizerbar, place the stabilizer bar backinto position and install the fourmounting bolts. Tighten fasteners to37 ft. lbs. (50 N·m).

65. For vehicles equipped with a C235axle and have a new ring andpinion, continue with Section C.Install Pinion Nut Retainer RingStep 7.

66. For Vehicles equipped with a 9.25axle or a C235 with the originalring and pinion, continue withSection C. Install Pinion NutRetainer Ring.


Figure 51 – Clean Axle Flange Hub

Figure 52 – Apply Anti-Seize Lubricant to AxleShaft Hub

AXLEFLANGE

AXLESHAFT HUB

AXLESHAFT

HUB

APPLY ANTI-SEIZELUBRICANT TO OUTERSURFACE OF THE AXLE

SHAFT HUB

Safety Recall N08

C. Install Pinion Nut Retainer Ring

NOTE: C235 axles that have a 12point pinion nut do not require apinion nut retainer ring. Do notinstall a pinion nut retainer ring onaxles with a 12 point pinion nut.

1. Thoroughly clean the companionflange bore around the pinion nut(Figure 53).

2. Using snap ring pliers, install thepinion nut retainer ring (Figure 54).


Figure 54 – Install Pinion Nut Retainer Ring

Figure 53 – Clean Companion Flange Bore

COMPANIONFLANGE BORE

COMPANIONFLANGE

PINION NUTRETAINER RING

COMPANIONFLANGE

PINION NUTSNAP RINGPLIERS

PINION SHAFT

Safety Recall N08

3. Using a small punch, gently tap the face of the pinion nut retainer ring to ensurethat it is completely seated in the companion flange bore (Figure 55).


Figure 55 – Gently Tap the Face of the Pinion Nut Retainer Ring to Ensure it isFully Seated in the Companion Flange Bore


SMALL PUNCH

COMPANIONFLANGE

Safety Recall N08

4. Using a small punch and hammer, gently rotate the pinion nut retainer ringclockwise until the pinion nut retainer ring seats against the flats/corners of thepinion nut (Figure 56).

CAUTION: Use extreme care not to damage the retaining ring whenrotating it into position with a punch and hammer.


Figure 56 – Rotate the Pinion Nut Retainer Ring Clockwise until Seated Against thePinion Nut Flats/Corners

COMPANIONFLANGE


PINION NUT

SMALLPUNCH

Safety Recall N08

5. Using the supplied hex-bits, snug the two set screws on the pinion nut retainerring.

6. Using an inch pound torque wrench, tighten each of the set screws on the pinionnut retainer ring in 5 in. lbs. increments, alternating back and forth (Figure 57).Continue alternating back and forth increasing the torque on the torque wrenchby 5 in. lbs. until 45 in. lbs. (5 N·m) is obtained on both set screws.

CAUTION: Failure to alternate between the two set screws during thetightening process will cause pinion nut retainer ring damage.

CAUTION: The supplied hex-bits will be stressed to their limit during thetightening process. Do not exceed 45 in. lbs. (5 N·m), hex-bit breakage willoccur. It is not uncommon for the hex-bit to break occasionally when thetightening torque reaches 45 in. lbs. (5 N·m). If the hex-bits continuouslybreak during installation, have your torque wrench calibration checkedand adjusted as required.


Figure 57 – Tighten Set Screws in 5 in. lbs. Increments Alternating Back and ForthUntil 45 in. lbs. (5 N·m) is Obtained on Each Set Screw

3/32 HEX-BITSUPPLIED INREPAIR KIT

INCH POUNDTORQUEWRENCH

PINION NUTRETAINER RING SET

SCREWS

Safety Recall N08

7. Install the propeller shaft into position. Install new propeller shaft retainingbolts and tighten them to 85 ft. lbs. (115 N·m).

8. For vehicles that had the rear axle reconditioned, partially lower the vehiclefrom the hoist.

9. For vehicles that had the rear axle reconditioned, install the rear tire andwheel assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N·m).

10. Lower the vehicle from the hoist.

11. For vehicles that had the rear axle reconditioned, perform the followingadditional steps:

a. Before moving the vehicle, apply the brakes several times to ensure that therear brake pads are against the brake rotor.

b. Road test the vehicle to ensure that the rear axle functions properly.

c. For vehicles with a Trac-Lok differential, road test the vehicle and make10 to 12 slow figure-eight turns in an empty parking lot or other safe area.This maneuver will pump the lubricant through the clutch discs to eliminate apossible rear axle chatter noise complaint.


Safety Recall N08

Claims for vehicles that have been serviced must be submitted on theDealerCONNECT Claim Entry Screen located on the Service tab. Claimssubmitted will be used by Chrysler to record Customer Satisfaction Notificationservice completions and provide dealer payments.

Parts listed on any campaign are required for the repair but may not always beeligible for reimbursement. As stated in the Service Administration Manual;Normal shop supplies, such as general-purpose cleaners, solvents, lubricants, etc.submitted on claims are subject to non-payment or chargeback.

Use the following labour operation numbers and time allowances:

Labour Operation TimeNumber Allowance

Inspect for 12 point pinion nut(C235 axles only) 03-N0-81-81 0.3 hours

Check pinion nut for looseness andinstall pinion nut retainer(C235 or 9.25 axles with 6 point nut) 03-N0-81-82 0.4 hours

Check pinion nut for looseness, reconditionrear axle and install pinion nut retainer(C235 with original ring and pinionor 9.25 axle) 03-N0-81-83 4.4 hours

Check pinion nut for looseness andrecondition rear axle(C235 axle with new ring and pinion) 03-N0-81-84 4.3 hours

Related Operation:

Replace one axle shaft, axle shaftbearing and axle shaft seal 03-N0-81-50 0.5 hours

Replace two axle shafts, axle shaftbearings and axle shaft seals 03-N0-81-51 1.0 hours

Replace differential case and/orinternal differential components 03-N0-81-52 0.1 hours

Trac-Lok equipped vehicles, road testvehicle and perform 10 - 12 figure-eightmaneuvers 03-N0-81-53 0.1 hours

Completion Reporting and Reimbursement

Safety Recall N08

All involved vehicle owners known to Chrysler are being notified of the service requirement by mail.They are requested to schedule appointments for this service with their dealers. A copy of the ownerletter is attached.

Enclosed with each owner letter is a Service Authorization Card to allow owners to update our records ifapplicable.

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) andVehicle Information Plus (VIP) for studio inquiry as needed.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name,address and phone number are listed if known. Completed vehicles are removed from GRS withinseveral days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.” Your studio’sVIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, thosewith a phone number, city, Postal Code, or VIN sequence.

Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should alsouse the VIN list to follow up with all owners to schedule appointments for this repair.

VIN lists may contain confidential, restricted owner name and address information. Use of thisinformation is permitted for this notification only and is strictly prohibited from all other use.

If you have any questions or need assistance in completing this action, please contact your Service andParts District Manager.

Chrysler Canada Inc.

J.D. KiritsisNational Service and Parts Manager

Owner Notification and Service Scheduling

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

Additional Information

Chrysler Canada Inc.

SAFETY RECALL N08REAR AXLE PINION NUT

Dear Chrysler Canada Vehicle Owner:

This notice (Follow up) is sent to you in accordance with the Canada Motor Vehicle Safety Act.

Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2009 through 2012 model yearRAM truck (1500 series) and Dodge Dakota; and 2009 Dodge Durango and Chrysler Aspen vehicles.

The problem is : The rear axle pinion nut may loosen due to undersized pinion splines. A loose pinion nutcould cause the rear axle to seize or cause the driveshaft to separate resulting in a lossof motive power. Either situation could cause a crash without warning.

What your dealerwill do :

Chrysler will service your vehicle free of charge (parts and labour). To do this, your dealerwill inspect the rear axle pinion nut and install a pinion nut retainer ring. If required reconditionthe rear axle.

What you must doto ensure yoursafety :

Contact your dealer to schedule a service appointment and provide them with your VINnumber, (shown on the enclosed Service Authorization Card).

If you need help : If you require additional assistance or information, please contact Chrysler Canada CustomerCare at 1-800-465-2001 (English) or 1-800-387-9983 (French) or by email :www.chryslercanada.ca/en/contact_us.php (English) orwww.chryslercanada.ca/fr/contact_us.php (French).

If you have already experienced this condition and have paid to have it repaired, you will still be required to have thecampaign performed by an authorized Chrysler dealer at no charge to you. Once completed, please send your originalreceipts and/or adequate proof of payment along with the campaign invoice to the following address for reimbursement:Chrysler Canada Customer Care, P.O. Box 1621, Windsor, ON, N9A 4H6.

If your name and address shown on the enclosed Service Authorization Card is incorrect or if you no longer own thevehicle, please contact us at the above phone number, email address or fill in the prepaid post card.

We apologize for any inconvenience and thank you for your attention to this important matter.

Yours very truly,

Chrysler Canada Inc.National Service and Parts Manager

September 2013 Dealer Service Instructions for: Safety ...

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