This procedure covers replacement of the front axle shaft seal on a 2014 Ram 2500 4WD with 6.7L Cummins Diesel, requiring removal of the axle shaft and CV joint.

Warnings

Tools required

Parts

• Front axle shaft seal × 1 — Use OEM specification for Dana front axle
• Differential cover gasket × 1 — Use OEM specification
• Cotter pin for axle nut × 1 — Use OEM specification if vehicle uses cotter pin

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheel on side requiring seal replacement

Procedure

1. 1

   Remove axle nut
   Remove and discard the cotter pin from the axle nut (or remove staking if applicable). Using a breaker bar and appropriate socket, remove the axle nut from the end of the axle shaft. This nut requires significant force to loosen. A new cotter pin or re-staking will be required upon reassembly.
2. 2

   Disconnect CV joint from differential
   Locate the CV joint bolts connecting the inner CV joint to the differential stub shaft. There are typically 6 bolts securing this connection. Remove all CV bolts and carefully support the axle shaft to prevent damage to the outer CV boot. The axle shaft assembly can now pivot away from the differential.
   Torque spec

   CV Bolts82 Nm (61 lb-ft)
3. 3

   Remove axle shaft assembly
   Pull the outer end of the axle shaft outward from the hub assembly while supporting the entire shaft. The axle shaft splines will disengage from the wheel hub. Once free, carefully remove the complete axle shaft assembly from the vehicle and set aside on a clean work surface. Position drain pan under differential opening.
   ⚠Gear oil will begin draining from the differential once the axle shaft is removed. Ensure drain pan is properly positioned.
4. 4

   Drain remaining differential fluid
   With the axle shaft removed, allow remaining gear oil to drain from the axle tube and differential. If a complete seal replacement is being performed, consider draining the differential completely by removing the differential cover. This provides better access and allows inspection of internal components. Remove differential cover bolts if performing complete drain.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
5. 5

   Remove old axle seal
   Using a seal puller or slide hammer with hook attachment, carefully extract the old axle seal from the axle tube. Hook the inner lip or edge of the seal and pull straight out. Avoid damaging the seal bore surface in the axle tube housing. If seal is stubborn, use a brass drift and hammer to carefully tap around the seal perimeter to break it free.
   ⚠Do not gouge or scratch the seal bore surface as this will cause the new seal to leak.
6. 6

   Clean and inspect seal bore
   Thoroughly clean the axle tube seal bore using a shop rag and wire brush. Remove all old seal material, debris, and corrosion. Inspect the bore for damage, grooves, or scoring that could compromise the new seal. Inspect the axle shaft sealing surface for wear, grooves, or damage. Replace axle shaft if sealing surface is compromised.
7. 7

   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, carefully drive the seal into the bore until it seats fully and is flush with the housing. Ensure seal is installed straight and not cocked.
   ⚠Drive seal only on the outer metal edge - never drive on the seal face or inner rubber as this will damage the seal.
8. 8

   Reinstall differential cover if removed
   If the differential cover was removed, clean the cover and housing mating surfaces thoroughly. Install a new differential cover gasket. Position the cover and install all differential cover bolts. Torque bolts in a criss-cross pattern to specification to ensure even gasket compression and prevent leaks.
   Torque spec

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

   Refill differential with gear oil
   Fill the front differential with the specified 75W-90 GL-5 gear oil. The front differential capacity is approximately 1.5 quarts. Fill until oil begins to seep from the fill plug opening or reaches the bottom of the fill plug hole when level. Install and tighten the fill plug.
10. 10

    Reinstall axle shaft assembly
    Lightly coat the axle shaft splines with gear oil. Carefully insert the outer end of the axle shaft into the wheel hub, aligning the splines. Push the shaft fully into the hub. Pivot the inner CV joint into position and align it with the differential stub shaft. The splines should align and engage smoothly.
11. 11

    Connect CV joint to differential
    With the inner CV joint aligned to the differential stub shaft, install all CV bolts through the CV joint flange. Thread bolts by hand first to ensure proper alignment. Torque all CV bolts to specification in a criss-cross pattern.
    Torque spec

    CV Bolts82 Nm (61 lb-ft)
12. 12

    Install and torque axle nut
    Install the axle nut onto the axle shaft threads at the wheel hub. Torque the axle nut to 250 Nm (184 ft-lb). Install a new cotter pin through the hole in the axle shaft and bend the ends to secure (or stake the nut if vehicle uses stake-type nut retention). Never reuse the old cotter pin.
    ⚠️Axle nut MUST be secured with new cotter pin or properly staked. Failure to properly secure this nut can result in wheel separation and loss of vehicle control.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Mount the wheel onto the hub and thread all lug nuts by hand. Tighten lug nuts in a star pattern with a torque wrench to specification. Lower the vehicle to the ground and perform final torque check on lug nuts in star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners have been torqued to specification
2. Verify axle nut is properly secured with new cotter pin or staking
3. Check that differential is filled to proper level with correct gear oil
4. Verify no tools or parts have been left in wheel well or under vehicle

Verification

• Start vehicle and turn steering lock-to-lock to verify no binding or unusual noises from axle
• Test drive vehicle and verify no vibration or clicking from front axle
• After test drive, inspect axle seal area for any signs of gear oil leakage
• Recheck differential fluid level after test drive and top off if necessary
• Inspect area around seal after 50-100 miles of driving to confirm no leakage

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