G648 Rear Axle

G648 REAR AXLE

Special Tools:











NOTE: Lubricate the inside diameter with Mopar(R) Gear and Axle Lubricant 75W-90 to protect seal during halfshaft installation.

1. If removed, install NEW axle shaft seals using Installer (2) and Handle (3).





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

4. Using new circlip(s), install left halfshaft (2) to rear axle assembly. Do not damage axle seals. Verify proper installation by pulling outward on joint by hand.





5. Using Seal Protector (3) install the right halfshaft (1) into axle (2).






NOTE: To prevent damage or imbalance, washers must be placed on fasteners that attach rubber coupler to the pinion yoke.

NOTE: To prevent damage or imbalance, washers must be installed between fastener heads and the rubber coupler.

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






NOTE: If re-using the original rear axle-to-crossmember bolts, clean the rear axle-to-crossmember bolts and apply a patch of blue MOPAR(R) Lock & Seal medium strength thread locker to the rear axle-to-crossmember bolts. New bolts have a thread lock patch, and do not require application of blue MOPAR(R) Lock & Seal medium strength thread locker

7. Install right rear axle-to-crossmember bolt (1) and tighten to 220 Nm (162 ft. lbs.).






NOTE: If re-using the original rear axle-to-crossmember bolts, clean the rear axle-to-crossmember bolts and apply a patch of blue MOPAR(R) Lock & Seal medium strength thread locker to the rear axle-to-crossmember bolts. New bolts have a thread lock patch, and do not require application of blue MOPAR(R) Lock & Seal medium strength thread locker

8. Install left rear axle-to-crossmember bolt (1) and tighten to 220 Nm (162 ft. lbs.).






NOTE: The rubber part of the axle isolator must face toward the cradle.

9. Install rear axle front mount isolator (3) as shown and torque fastener to 65 Nm (48 ft. lbs.).





10. Install the front mount bolt cover (1).





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






NOTE: If re-using original fasteners, apply a patch of blue MOPAR(R) Lock & Seal medium strength thread locker to the propeller shaft coupler-to-axle flange fasteners. New fasteners have a thread lock patch, and do not require application of blue MOPAR(R) Lock & Seal medium strength thread locker.

14. Install the propeller shaft coupler-to-axle flange fasteners. Tighten the propeller shaft coupler-to-axle flange fasteners (2) to 122 Nm (89 ft. lbs.).





15. Remove fill plug (2) to check and adjust rear axle fluid level. Top off axle with Mopar(R) Gear and Axle Lubricant 75W-90. Reinstall fill plug and torque to 35 Nm (25 ft. lbs.) torque.





16. Lower vehicle. Torque halfshaft hub nut (1) to 213 Nm (157 ft. lbs.). Install wheel center cap.
17. Install wheel(s) Tires And Wheels - Installation