Axle Seal - Front

This procedure covers replacement of the front axle shaft seal on a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine, requiring removal of the CV axle shaft and installation of a new seal into the differential housing.

Warnings

Tools required

Parts

• Front axle shaft seal × 1 — Use OEM specification for Dana 60 front axle
• Cotter pin for axle nut × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification or RTV silicone

Fluids

• 75W-90 synthetic gear oil — 3.5 qt

Preparation

1. Park vehicle on level ground and set parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on the ground
4. Raise front of vehicle and support on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Allow differential to cool completely if vehicle was recently driven

Procedure

1. 1

   Remove axle nut and cotter pin
   To access the front axle shaft on the Dana 60 solid axle, first remove the front wheel, brake caliper, and rotor. Remove the hub/unit bearing retaining bolts and disconnect the tie rod/steering as required, then pull the outer knuckle/hub assembly to free the outer end of the axle shaft. Follow the shop manual for the specific hub and spindle nut retention hardware used on your model year.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
2. 2

   Disconnect CV joint from axle shaft
   There are no CV joints on this solid Dana 60 front axle. The axle shaft is a one-piece (or two-piece with U-joint) shaft that slides into the differential. To remove it, disassemble the steering knuckle/hub as needed to free the outer end, then withdraw the axle shaft from the axle tube. Support the shaft to avoid damaging the U-joint or seal surface.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
3. 3

   Drain front differential
   Position a drain pan under the front differential cover. Remove the differential cover bolts starting from the top and working downward, leaving 2-3 bolts at the top partially threaded. Carefully break the seal and allow fluid to drain. Once drained, remove remaining bolts and cover. Clean the gasket surfaces thoroughly with a wire brush and scraper. Gear oil will drain quickly once the cover seal breaks. Position drain pan to catch approximately 3.0-3.25 quarts of fluid (verify exact capacity for your Dana 60 axle).
   ⚠Gear oil will drain quickly once the cover seal breaks. Position drain pan to catch approximately 3.5 quarts of fluid.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
4. 4

   Remove axle shaft from hub
   After disassembling the steering knuckle and hub as required, withdraw the axle shaft assembly (with U-joint) outward from the axle tube and differential. Support the shaft carefully to avoid nicking the seal contact surface as it passes through the seal.
   ℹ️Some resistance is normal as the shaft slides through the seal. Do not damage the shaft surface that contacts the seal during removal.
5. 5

   Remove old axle seal
   Using a slide hammer with seal puller attachment, hook behind the old seal and extract it from the axle tube. If a slide hammer is not available, carefully pry the seal out using a large screwdriver or pry bar, taking care not to damage the axle tube bore. Clean the seal bore thoroughly with a wire brush and solvent, removing all old seal material and debris.
   ⚠Do not gouge or scratch the seal bore surface as this will cause the new seal to leak.
6. 6

   Install new axle seal
   Lightly coat the outer diameter of the new seal with gear oil. Position the seal squarely in the axle tube bore with the seal lip facing inward toward the differential. Using a seal driver or large socket that contacts only the outer edge of the seal, drive the seal in until it is fully seated and flush with the axle tube face. Tap evenly around the circumference to ensure proper seating.
   ⚠Do not strike the seal face directly as this will damage the sealing element. Only apply force to the outer metal ring.
7. 7

   Inspect and reinstall axle shaft
   Inspect the axle shaft seal surface for grooves, pitting, or damage. If the shaft shows wear in the seal contact area, it must be replaced. Coat the seal surface of the axle shaft with clean gear oil. Carefully slide the axle shaft through the new seal and into the differential, ensuring the splines engage properly with the side gear. Push the outer end into the wheel hub until fully seated.
   ℹ️The shaft must slide through the seal without catching or binding. If resistance is felt, remove and inspect for proper seal installation.
8. 8

   Reinstall differential cover
   Install a new differential cover gasket or apply a 1/8 inch bead of RTV silicone to the cover flange. Position the cover on the differential housing and install all cover bolts finger tight. Torque the cover bolts in a crisscross pattern to approximately 30-40 lb-ft (verify exact spec for your Dana 60) to ensure even gasket compression.
   ℹ️If using RTV silicone, wait 15-20 minutes before torquing bolts to allow silicone to set slightly.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
9. 9

   Reconnect CV joint to axle shaft
   Align the CV joint flange with the axle shaft flange. Install all CV joint bolts and torque in a star pattern to ensure even loading.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
10. 10

    Install and torque axle nut
    Reinstall the steering knuckle, hub/unit bearing, and spindle nut hardware per the shop manual, torquing the hub bearing bolts and any spindle nut to specification. There is no external cotter-pinned axle nut on this solid Dana 60 front axle.
    ⚠The cotter pin hole must align with the castellation in the nut. If it does not align, tighten the nut slightly until the next castellation aligns. Never loosen the nut to align the hole.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
11. 11

    Refill front differential
    Using a fluid pump or squeeze bottle, add the factory-specified gear oil (typically 75W-90/80W-90, verify grade) through the fill plug opening until fluid begins to drip from the fill hole. The front differential requires approximately 3 quarts. Install the fill plug and torque to specification if a torque spec is available for your specific axle model.
    ℹ️The fill hole is located on the front or side of the differential housing. Fluid level is correct when it reaches the bottom of the fill hole threads.
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the tire just touches the ground. Torque the lug nuts in a star pattern to specification. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all fasteners have been torqued to specification
2. Verify the axle nut cotter pin is properly installed and secured
3. Check for any tools or parts left in the work area
4. Dispose of used gear oil according to local regulations

Verification

• Start the engine and verify no unusual noises from the front axle
• Test drive the vehicle and verify proper 4WD operation
• After driving 50-100 miles, inspect the axle seal area and differential cover for any signs of leakage
• Check front differential fluid level after test drive and top off if necessary
• Verify the axle nut cotter pin remains secure after test drive

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