CV Axles - Front Pair

This procedure covers removal and replacement of both front CV axle assemblies on the 4WD Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Front CV axle assembly - driver side × 1 — OEM or aftermarket equivalent for 4WD 2500
• Front CV axle assembly - passenger side × 1 — OEM or aftermarket equivalent for 4WD 2500
• Axle hub nut × 2 — Use OEM specification
• Cotter pin for axle nut (if equipped) × 2 — Use OEM specification
• Ball joint nut (if reuse not recommended) × 2 — Use OEM specification

Fluids

• 75W-90 synthetic gear oil — 3.5 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Place wheel chocks behind rear wheels
3. Loosen both front axle hub nuts while vehicle is still on ground (1-1/4 inch or 36mm socket required)
4. Loosen front wheel lug nuts on both sides
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove both front wheels completely
7. Remove skid plate if equipped to access front differential and CV axles
8. Spray all fasteners to be removed with penetrating oil and allow to soak

Procedure

1. 1

   Remove axle hub nuts
   With vehicle raised and secured, completely remove both front axle hub nuts that were previously loosened. Remove and discard cotter pins if equipped. Set aside old nuts as new ones are recommended for reassembly.
2. 2

   Disconnect steering knuckle ball joints
   Remove the ball joint nuts from the upper and lower ball joints connecting the steering knuckle to the axle yoke (axle-C) on both sides. Use a ball joint separator or pickle fork to separate the ball joint from the steering knuckle. Apply steady pressure and strike tool sharply if needed. The knuckle must be free to pivot away from the hub assembly.
   ⚠Ball joint may release suddenly under pressure. Keep hands and face clear of pinch points.
3. 3

   Support steering knuckle and hub assembly
   Once ball joint is separated, carefully pivot the steering knuckle and hub assembly outward. Support it with wire or bungee cord to prevent strain on brake hose and ABS sensor wire. Do not let assembly hang by brake or sensor lines.
4. 4

   Remove inner CV joint bolts - driver side
   Locate the inner axle shaft where it enters the front differential/axle tube. The solid-axle shafts are splined into the differential and are not retained by flange bolts. Refer to the correct Dana axle service procedure for shaft removal (typically involves removing the axle shaft assembly through the knuckle after unbolting the outer components).
   ⚠Differential fluid may leak when CV joint is separated. Position drain pan underneath.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
5. 5

   Remove driver side CV axle
   After removing the hub/unit bearing and knuckle components, withdraw the front axle shaft (with U-joint and stub shaft) straight out of the axle tube. Some fluid may weep from the tube; position a drain pan.
6. 6

   Remove inner CV joint bolts - passenger side
   Repeat the process on the passenger side. Remove all 6 bolts securing the inner CV joint to the differential flange. Rotate axle as necessary to access all fasteners.
   ⚠Additional fluid may drain on passenger side. Keep drain pan positioned.
   Torque spec

   CV Joint Bolts61 Nm (45 lb-ft)
7. 7

   Remove passenger side CV axle
   Pull the outer CV joint shaft through the hub bearing while separating the inner CV joint from the differential. Use pry bar if needed to break seal. Remove entire axle assembly through steering knuckle. Plug differential opening with clean shop towel.
8. 8

   Clean mounting surfaces
   With both axles removed, thoroughly clean all mounting surfaces. Use wire brush on differential flanges, hub splines, and ball joint tapers. Remove any old thread locker from bolt holes. Inspect hub bearings for roughness or play; replace if needed. Inspect differential seals for damage.
9. 9

   Install new driver side CV axle
   Remove shop towel from driver side differential opening. Insert inner CV joint into differential and align bolt holes with flange. Push outer CV joint shaft through hub bearing until fully seated. Ensure splines engage properly in hub. Install all 6 inner CV joint bolts finger tight. Torque bolts in star pattern to specification.
   Torque spec

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

    Install new passenger side CV axle
    Remove shop towel from passenger side differential opening. Insert inner CV joint into differential and align bolt holes with flange. Push outer CV joint shaft through hub bearing until fully seated. Install all 6 inner CV joint bolts finger tight. Torque bolts in star pattern to specification.
    Torque spec

    CV Joint Bolts61 Nm (45 lb-ft)
11. 11

    Reconnect steering knuckles
    Remove support wire/bungee and pivot each steering knuckle back into position. Insert ball joint studs into knuckle tapers and install new castle nuts. Torque ball joint nuts to specification. Install new cotter pins if equipped, or ensure staked nuts are properly secured per design.
    Torque spec

    Lower Ball Joint Nut102 Nm (75 lb-ft)
12. 12

    Install new axle hub nuts
    Install new axle hub nuts on both sides and tighten snug but do not torque yet. Final torque will be performed with vehicle on ground.
13. 13

    Check and refill front differential
    Remove front differential fill plug and check fluid level. Add the manufacturer-specified gear oil (verify spec — typically 75W-90 or 80W-90 GL-5) until fluid reaches the bottom of the fill hole. Reinstall fill plug. Verify total capacity against the specific front axle (Dana 44 or Dana 60) service data.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall skid plate if equipped. Install both front wheels and thread lug nuts by hand. Lower vehicle to ground. Torque wheel lug nuts in star pattern to specification.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)
15. 15

    Final torque axle hub nuts
    With vehicle on ground and parking brake applied, torque both front axle hub/stub nuts to the manufacturer-specified value for the specific year and axle (verify against the service manual). Secure per design (cotter pin or staking).
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. Ensure all CV joint bolts are torqued in star pattern to prevent warping flanges
2. Verify ball joint nuts are properly secured with cotter pins or staking
3. Double-check that axle hub nuts are torqued to full specification with vehicle on ground
4. Confirm no differential fluid leaks from inner CV joint seals

Verification

• Test drive vehicle and listen for clicking or popping from CV joints during turns
• Verify smooth operation with no vibration at highway speeds
• Check for any fluid leaks around differential and inner CV joint seals after test drive
• Confirm proper 4WD engagement if equipped with selectable system
• Re-check axle hub nut torque after 50-100 miles of driving

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