Page 89 of 2255

REMOVAL
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove shift motor housing cover, gasket and
shield from the housing (Fig. 27).
DISASSEMBLY
(1) Remove E-clips from the shift motor housing
and shaft. Remove shift motor and shift fork from
the housing (Fig. 28).
(2) Remove O-ring seal from the shift motor shaft.
(3) Clean and inspect all components. Replaced
any component that is excessively worn or damaged.
ASSEMBLY
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert shift motor shaft through the hole in the
housing and shift fork. The shift fork offset should be
toward the differential.
(3) Install E-clips on the shift motor shaft and
housing.
INSTALLATION
(1) Install shift motor housing gasket.
(2) Guide the shift fork onto the shift collar groove,
while install the shift motor housing cover.
(3) Install shift motor housing shield and tighten
the bolts to 11 N´m (96 in. lbs.).(4) Add 148 ml (5 ounces) of API grade GL 5
hypoid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(5) Install indicator switch, electrical connector
and vacuum harness.
SINGLE CARDAN UNIVERSAL
JOINTS
REMOVAL
Single cardan U-joint components are not service-
able. If defective they must be replaced as a unit.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 29).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket with an inside diameter is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
(4) Locate a socket with an outside diameter is
smaller than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap.
Fig. 27 SHIFT MOTOR HOUSING
1 - INDICATOR LAMP SWITCH
2 - DISCONNECT HOUSING
3 - VACUUM SHIFT MOTOR
4 - AXLE SHAFT
5 - SEAL
6 - SHIFT COLLAR
7 - SHIFT FORK
8 - BEARING
9 - INTERMEDIATE AXLE SHAFT
Fig. 28 SHIFT MOTOR COMPONENTS
1 - INDICATOR SWITCH
2 - E-CLIP
3 - O-RING
4 - SHIFT MOTOR
5 - SHIFT FORK
6 - VACUUM PORTS
7 - DISCONNECT HOUSING AND GASKET
3 - 34 FRONT AXLE - 248FBIBR/BE
AXLE VACUUM MOTOR (Continued)
Page 90 of 2255

(5) Position the yoke with the sockets in a vise
(Fig. 30).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake calipers and rotors
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 31) .
(9) Use suitable pry tool or slide hammer mounted
screw to remove the pinion shaft seal.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 32).
(2) Install yoke on the pinion gear with Installer
C-3718 and Holder 6719 (Fig. 33).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining
nut. Damage to collapsible spacer or bearings may
result.
Fig. 29 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET WRENCH
2 - VISE
3 - SMALL-DIAMETER SOCKET WRENCH
BR/BEFRONT AXLE - 248FBI 3 - 35
SINGLE CARDAN UNIVERSAL JOINTS (Continued)
Page 91 of 2255

(3) Install a new nut on the pinion gear. Tighten
the nut only enough to remove the shaft end play.
(4) Rotate the pinion shaft using an inch pound
torque wrench. Rotating torque should be equal to
the reading recorded during removal, plus an addi-
tional 0.56 N´m (5 in. lbs.) (Fig. 34).
(5) If the rotating torque is to low, use Holder 6719
to hold the pinion yoke (Fig. 35), and tighten the pin-
ion shaft nut in 6.8 N´m (5 ft. lbs.) until proper rotat-
ing torque is achieved.
(6) Align the installation reference marks and
attach the propeller shaft to the yoke.
(7) Check and add lubricant to axle, if necessary.
Refer to Lubricant Specifications in this section for
lubricant requirements.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
Fig. 31 Pinion
1 - YOKE HOLDER
2 - YOKE
3 - YOKE PULLER
Fig. 32 Pinion Seal Installation
1 - HANDLE
2 - INSTALLER
Fig. 33 PINION YOKE
1 - INSTALLER
2 - YOKE HOLDER
Fig. 34 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
3 - 36 FRONT AXLE - 248FBIBR/BE
PINION SEAL (Continued)
Page 92 of 2255

DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential housing cover.
(3) Remove differential housing cover and drain
the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove hub bearings and axle shafts.
(6) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 36).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 37).
(9) Install the hold down clamps and tighten the
spreader turnbuckle finger-tight.
(10) Install Pilot Stud C-3288-B to the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 37) and zero the
dial indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 37).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If the housing is over-spread it could be
distorted or damaged.
(12) Remove the dial indicator.
Fig. 35 PINION SHAFT NUT
1 - PINION FLANGE
2 - YOKE HOLDER
3 - DIFFERENTIAL HOUSING
Fig. 36 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 37 SPREAD DIFFERENTIAL HOUSING
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
BR/BEFRONT AXLE - 248FBI 3 - 37
PINION SEAL (Continued)
Page 93 of 2255

(13) Pry the differential case loose from the hous-
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 38).
(14) Remove the case from housing.
(15) Remove and tag bearing cups to indicate their
location.
DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 39).
(3) Rotate differential side gears and remove pin-
ion mate gears and thrust washers (Fig. 40).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align hole in the pinion gear mate shaft with
hole in the differential case.
(5) Install and seat pinion mate shaft roll-pin in
the differential case and mate shaft with a punch
and hammer (Fig. 41). Peen the edge of the roll-pin
hole in the differential case slightly in two places
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
Fig. 38 DIFFERENTIAL REMOVAL
1 - DIFFERENTIAL
2-PRYBAR
Fig. 39 PINION MATE SHAFT
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
Fig. 40 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
3 - 38 FRONT AXLE - 248FBIBR/BE
DIFFERENTIAL (Continued)
Page 94 of 2255

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) procedures to determine proper shim
selection.
(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes. Install the hold
down clamps and tighten the tool turnbuckle finger-
tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the dial indica-
tor.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could be dis-
torted or damaged.
(4) Remove the dial indicator.(5) Install differential into the housing. Tap the
differential case with a rawhide/rubber hammer to
ensure the bearings are seated in housing (Fig. 42).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 43) and tighten bearing cap bolts in a criss-
cross pattern to 109 N´m (80 ft. lbs.).
(8) Install axle shafts.
(9) Install the hub bearings.
Fig. 41 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 42 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 43 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
BR/BEFRONT AXLE - 248FBI 3 - 39
DIFFERENTIAL (Continued)
Page 95 of 2255

(10) Apply a bead of red Mopar Silicone Rubber
Sealant or equivalent to the housing cover (Fig. 44).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied or adhesion quality will be compro-
mised.
(11) Install the cover and tighten bolts in a criss-
cross pattern to 47 N´m (35 ft. lbs.).
(12) Fill the differential with Mopar Hypoid Gear
Lubricant or equivalent to bottom of the fill plug
hole.
(13) Install fill hole plug and tighten to 34 N´m (25
ft. lbs.).
(14) Remove support and lower vehicle.DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-62 and
Step Plate C-4487-1 (Fig. 45).
Fig. 44 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 45 Differential Bearing Removal
1 - PULLER
2 - ADAPTERS
3 - STEP PLATE
4 - BEARING
5 - DIFFERENTIAL CASE
3 - 40 FRONT AXLE - 248FBIBR/BE
DIFFERENTIAL (Continued)
Page 96 of 2255

INSTALLATION
(1) Install differential side bearings with Installer
C-4190 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the match pinion gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from differential case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 47).
(5) Mark pinion yoke and propeller shaft for
installation alignment.(6) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(7) Hold pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(8) Remove pinion yoke with Puller C-452 and
Flange Wrench C-3281 (Fig. 48).
Fig. 46 Install Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 47 RING GEAR
1 - CASE
2 - RING GEAR
3 - HAMMER
Fig. 48 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - PULLER
BR/BEFRONT AXLE - 248FBI 3 - 41
DIFFERENTIAL CASE BEARINGS (Continued)