This procedure covers removal and replacement of the rear axle shaft on a 2014 Ram 2500 with 6.7L Cummins diesel and 4WD, including differential cover removal, axle extraction, and reassembly with proper torque specifications.

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification for AAM 11.5" rear axle
• Axle shaft bearing × 1 — Use OEM specification
• Axle shaft seal × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM or RTV sealant
• Axle nut cotter pin × 1 — Use OEM specification
• Brake cleaner × 1 — Aerosol can

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2 qt

Preparation

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

Procedure

1. 1

   Remove brake caliper and rotor
   Remove brake caliper mounting bolts and hang caliper from frame with wire or bungee cord to avoid stressing the brake hose. Slide brake rotor off the hub. If rotor is stuck, use penetrating oil and tap with dead blow hammer.
2. 2

   Remove axle nut and washer
   Remove and discard the cotter pin from the axle nut. Use a breaker bar and appropriate socket to remove the axle nut from the end of the axle shaft. Remove the washer behind the nut. Mark the relationship of the hub to the axle shaft for reference.
   ℹ️The axle nut is torqued to 250 Nm and may require significant force to remove. A new cotter pin must be used during reassembly.
3. 3

   Position drain pan and remove differential cover
   Place drain pan under differential cover. Remove all differential cover bolts in a crisscross pattern to avoid warping. Carefully pry cover away from axle housing and allow gear oil to drain completely. Once drained, remove cover and gasket material.
   ⚠Approximately 2 quarts of hot gear oil will drain. Ensure drain pan has adequate capacity and positioning.
   Torque spec

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

   Clean differential cover and housing surfaces
   Use gasket scraper to remove all old gasket material and RTV from both the differential cover and axle housing mating surfaces. Clean surfaces with brake cleaner and wipe dry. Inspect cover for cracks or damage.
5. 5

   Remove differential pinion shaft lock bolt
   Locate the differential pinion shaft lock bolt inside the differential case. Remove the bolt and carefully slide the pinion shaft out of the carrier. Keep track of this bolt as it will be reused. Rotate the axle shaft to align the C-clip opening with the differential case opening.
6. 6

   Remove axle shaft C-clip
   Push the axle shaft inward toward the center of the vehicle to expose the C-clip that retains the axle shaft in the differential. Use a magnetic pick or needle-nose pliers to remove the C-clip from the recessed groove on the inner end of the axle shaft. Store the C-clip in a safe location if reusing.
   ⚠C-clips can be difficult to remove and may spring out. Wear safety glasses and maintain control of the C-clip.
7. 7

   Extract axle shaft from housing
   Carefully pull the axle shaft straight out of the axle housing tube. If the shaft resists removal, use a slide hammer with axle puller attachment threaded into the axle shaft flange bolt holes. Apply steady pulling force to extract the shaft, bearing, and seal as an assembly. Support the weight of the shaft during removal.
   ⚠Axle shaft weighs approximately 30-40 lbs and extends over 3 feet. Use proper lifting technique and maintain control.
8. 8

   Remove and inspect bearing and seal
   Using a bearing separator or press, remove the bearing from the axle shaft. Inspect the axle shaft splines, bearing surface, and seal contact area for wear, scoring, or damage. Replace shaft if any damage is found. Remove the old seal from the axle housing using a seal puller or slide hammer with seal puller attachment.
9. 9

   Install new bearing and seal on axle shaft
   Press or drive the new bearing onto the axle shaft using appropriate bearing installation tools until it seats against the shoulder. Ensure bearing is square and fully seated. Apply a thin coat of gear oil to the new seal lip. Drive the new seal into the axle housing using a seal driver that matches the outer diameter of the seal. Drive seal in until it is flush with or slightly below the housing face.
   ℹ️Bearing must be installed with the correct orientation. Verify bearing manufacturer markings face outward before installation.
10. 10

    Install axle shaft into housing
    Lubricate the axle shaft bearing surface and seal contact area with gear oil. Carefully guide the axle shaft into the housing, being careful not to damage the seal lip. Push the shaft in until the splines engage with the differential side gear. Rotate the shaft slightly while pushing to ensure full engagement.
11. 11

    Install C-clip and pinion shaft
    Push the axle shaft inward toward the center of the vehicle and install the C-clip into the groove on the inner end of the axle shaft. Pull the shaft outward to verify the C-clip is properly seated. Rotate the axle shafts to align the pinion shaft hole in the differential case. Install the pinion shaft through the case and install the lock bolt. Torque the pinion shaft lock bolt to specification.
12. 12

    Install differential cover with new gasket
    Apply a continuous bead of RTV silicone (approximately 1/8 inch thick) to the differential cover mating surface, circling all bolt holes. Alternatively, use a new pre-cut gasket if available. Position cover onto housing and install all bolts finger-tight. Torque bolts in a crisscross pattern to ensure even gasket compression and prevent warping.
    ℹ️If using RTV, allow 15-20 minutes cure time before filling with gear oil. Follow RTV manufacturer instructions.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
13. 13

    Fill differential with gear oil
    Remove the differential fill plug located on the front of the axle housing. Using a fluid pump or squeeze bottle, add Mopar 75W-140 Synthetic Gear Lubricant until oil begins to drip from the fill hole. Oil level should be at the bottom of the fill hole. Install fill plug and torque to specification.
14. 14

    Install hub components and axle nut
    Install washer onto axle shaft threads. Thread new axle nut onto shaft and torque to specification using a torque wrench. Install a new cotter pin through the hole in the axle shaft, bending the ends to secure. Verify cotter pin is properly seated and will not interfere with hub components.
    ℹ️Never reuse the old cotter pin. Always install a new cotter pin after torquing the axle nut.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
15. 15

    Reinstall brake components and wheels
    Install brake rotor onto hub. Remove caliper from its suspended position and reinstall over rotor, torquing mounting bolts to specification. Install wheel onto hub and thread lug nuts by hand. Lower vehicle slightly so tire contacts ground but weight is still on jack stands. Torque lug nuts in a star pattern to specification. Completely lower vehicle and perform final torque check on lug nuts.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque all fasteners in the sequence specified using a calibrated torque wrench
2. Always use new cotter pins and safety hardware
3. Allow RTV sealant to cure per manufacturer specifications before filling with gear oil
4. Check differential fluid level after test drive and top off if necessary

Verification

• Start vehicle and verify no leaks from differential cover or axle seal
• Test drive vehicle at low speed and verify no unusual noises, vibrations, or handling issues
• Perform figure-eight turns in both directions to verify axle engagement under load
• Re-inspect differential cover and axle seal for leaks after test drive
• Verify parking brake functions correctly
• Check differential fluid level and top off if necessary after initial test drive

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