CV Axle - Front

This procedure covers removal and installation of the front CV axle on a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine, including disconnecting the axle from the differential and removing it from the hub assembly.

Warnings

Tools required

Parts

• Front CV axle assembly × 1 — OEM or aftermarket equivalent for 4WD Ram 2500
• CV axle nut × 1 — Must be replaced - do not reuse
• Cotter pin or stake-type nut × 1 — Verify nut type for your year
• Ball joint nut × 1 — Replace if damaged during removal

Fluids

• 75W-90 synthetic gear oil — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. With vehicle on ground and wheel installed, use breaker bar and 36mm socket to loosen (but do not remove) the front axle nut
4. Loosen wheel lug nuts while vehicle is on the ground
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove wheel and tire assembly completely
7. Place drain pan under differential area to catch any escaping gear oil

Procedure

1. 1

   Remove axle nut
   With the vehicle raised and wheel removed, remove the front hub/axle nut (verify socket size against the service manual for your year and hub design). If the nut is staked, use a chisel or punch to unstake it first. Replace the nut per manufacturer guidance.
2. 2

   Disconnect ball joint from knuckle
   Ball joint disconnection is generally NOT required to remove the solid front axle shaft; the shaft slides out of the axle tube once the hub/spindle assembly is removed. If knuckle removal is needed, refer to the service manual for ball joint fastener sizes and torque for your year.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)

   Ball Joint Pinch Bolt55 Nm (41 lb-ft)
3. 3

   Disconnect CV axle from differential
   On the solid front axle, the inner axle shaft slides into the differential carrier and is retained by a snap ring or the differential internals; there is no bolted inner flange. Depending on Dana 60 configuration, remove the axle intermediate shaft/inner shaft retention as specified by the service manual before sliding the shaft out. A small amount of differential fluid may weep when the inner axle shaft is slid out. Have a drain pan ready and check the front axle fluid level after reassembly.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
4. 4

   Remove hub assembly connection
   Remove the unit bearing/hub bolts and spindle to access the axle shaft, then slide the U-joint axle shaft out of the axle tube. Do not damage the hub bearing or ABS sensor (if equipped) during removal.
5. 5

   Remove CV axle assembly
   Carefully maneuver the CV axle assembly out from underneath the vehicle. The axle must be angled and rotated to clear the differential housing, suspension components, and frame. Note the routing path for reinstallation. Inspect the differential seal for damage or leakage.
6. 6

   Clean and inspect mating surfaces
   Clean the hub splines, differential flange, and all mounting surfaces with a wire brush. Remove any rust, debris, or old thread locker. Inspect the differential output seal - replace if damaged or leaking. Check the hub bearing for play or roughness. Apply a thin coat of anti-seize to the hub splines.
7. 7

   Install new CV axle
   Carefully guide the new CV axle into position, reversing the removal path. Insert the outer splined end into the wheel hub first, ensuring it seats fully into the hub bearing. Align the inner CV joint with the differential flange, ensuring proper orientation of bolt holes.
8. 8

   Connect CV axle to differential
   Slide the axle shaft back into the axle tube and engage it fully into the differential carrier (seating the snap ring or retention as applicable). There are no inner flange bolts on the solid front axle.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
9. 9

   Reconnect ball joint to knuckle
   Raise the lower control arm or knuckle to align the ball joint taper with the knuckle bore. Insert the ball joint stud fully into the knuckle. Install the ball joint nut or pinch bolt and torque to specification. If using a castellated nut, install a new cotter pin through the nearest alignment slot.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)

   Ball Joint Pinch Bolt55 Nm (41 lb-ft)
10. 10

    Install and torque axle nut
    Install the NEW axle nut onto the CV axle shaft threads. Use a 36mm socket and torque wrench to torque the nut to specification. If using a stake-type nut, use a punch and hammer to stake the nut collar into the axle shaft groove. If using a castellated nut, install a new cotter pin.
    Torque spec

    Axle Nut244 Nm (180 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Hand-thread all lug nuts to ensure proper seating. Torque lug nuts in a star pattern to specification. Lower the vehicle to the ground and perform a final torque check on lug nuts with the vehicle weight on the wheels.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure the axle nut is properly staked or has a new cotter pin installed to prevent loosening
2. Verify all CV joint bolts are torqued evenly to prevent vibration
3. Check front differential fluid level and top off with 75W-90 synthetic gear oil if needed

Verification

• Check differential fluid level through fill plug - top off if necessary after test drive
• Test drive vehicle and verify no vibration, clicking, or unusual noises from front axle during acceleration and turning
• Verify no gear oil leakage from differential output seal after test drive
• Recheck wheel lug nut torque after 50-100 miles of driving
• Inspect CV axle boots for proper sealing and no damage

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