Dodge Durango (DN). Manual - part 220

ferential pinion mate shaft is retained with a roll-
pin. Differential bearing preload and ring gear
backlash is adjusted by the use of shims (select thick-

ness). The shims are located between the differential
bearing cups and the axle housing. Pinion bearing
preload is set and maintained by the use of a collaps-
ible spacer.

OPERATION

The axle receives power from the transfer case

through the front propeller shaft. The front propeller
shaft is connected to the pinion gear which rotates
the differential through the gear mesh with the ring
gear bolted to the differential case. The engine power
is transmitted to the axle shafts through the pinion
mate and side gears. The side gears are splined to
the axle shafts.

LUBRICANT

DESCRIPTION

A multi–purpose, hypoid gear lubricant which con-

forms to the following specifications should be used.
Mopar

t Hypoid Gear Lubricant conforms to all of

these specifications.

• The lubricant should have MIL–L–2105C and

API GL 5 quality specifications.

• Lubricant is a thermally stable SAE 80W–90

gear lubricant.

The C205F axle lubricant capacity is 1.66 L (3.5

pts.).

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C205F AXLE

CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.

STANDARD DIFFERENTIAL

DESCRIPTION

The differential gear system divides the torque

between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.

Each differential side gear is splined to an axle

shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.

OPERATION

In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear

• The ring gear (bolted to the differential case)

rotates the case

• The differential pinion gears (mounted on the

pinion mate shaft in the case) rotate the side gears

• The side gears (splined to the axle shafts) rotate

the shafts

During straight-ahead driving, the differential pin-

ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).

When turning corners, the outside wheel must

travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.

DIAGNOSIS AND TESTING

GENERAL INFORMATION

Axle bearing problem conditions are usually caused

by:

• Insufficient or incorrect lubricant.

• Foreign matter/water contamination.

• Incorrect bearing preload torque adjustment.

• Incorrect backlash.
Axle gear problem conditions are usually the result

of:

• Insufficient lubrication.

• Incorrect or contaminated lubricant.

• Overloading (excessive engine torque) or exceed-

ing vehicle weight capacity.

• Incorrect clearance or backlash adjustment.
Axle component breakage is most often the result

of:

• Severe overloading.

• Insufficient lubricant.

• Incorrect lubricant.

• Improperly tightened components.

• Differential housing bores not square to each

other.

Fig. 1 Differential Operation—Straight Ahead Driving

1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT

100% OF CASE SPEED

2 – PINION GEAR
3 – SIDE GEAR
4 – PINION GEARS ROTATE WITH CASE

Fig. 2 Differential Operation—On Turns

1 – PINION GEARS ROTATE ON PINION SHAFT

C205F AXLE

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DESCRIPTION AND OPERATION (Continued)

DIAGNOSTIC CHART

Condition

Possible Causes

Correction

Wheel Noise

1. Wheel loose.

1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing.

2. Replace bearing.

Axle Shaft Noise

1. Misaligned axle tube.

1. Inspect axle tube alignment.
Correct as necessary.

2. Bent or sprung axle shaft.

2. Inspect and correct as necessary.

3. End-play in pinion bearings.

3. Refer to pinion pre-load
information and correct as
necessary.

4. Excessive gear backlash
between the ring gear and pinion.

4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.

5. Improper adjustment of pinion
gear bearings.

5. Adjust the pinion bearings
pre-load.

6. Loose pinion companion flange
nut.

6. Tighten the pinion companion
flange nut.

7. Scuffed gear tooth contact
surfaces.

7. Inspect and replace as
necessary.

Axle Shaft Broke

1. Misaligned axle tube.

1. Replace the broken shaft after
correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid
excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid
or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and inspect
and repair clutch as necessary.

Differential Cracked

1. Improper adjustment of the
differential bearings.

1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.

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C205F AXLE

DIAGNOSIS AND TESTING (Continued)

Condition

Possible Causes

Correction

Differential Gears Scored

1. Insufficient lubrication.

1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

3. Excessive spinning of one
wheel/tire.

3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.

Loss Of Lubricant

1. Lubricant level too high.

1. Drain lubricant to the correct
level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored companion flange.

5. Replace companion flange and
seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal
cover.

Axle Overheating

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct
fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.

Gear Teeth Broke

1. Overloading.

1. Replace gears. Examine other
gears and bearings for possible
damage.

2. Erratic clutch operation.

2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine
remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

C205F AXLE

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DIAGNOSIS AND TESTING (Continued)

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