Complete removal and replacement of the front differential assembly on a 2014 Ram 2500 with 6.7L Cummins diesel, including axle shaft disconnection, driveshaft removal, and differential housing removal from the vehicle.

Warnings

Tools required

Parts

• Front differential assembly (if replacing complete unit) × 1 — Use OEM specification or remanufactured unit
• Differential cover gasket × 1 — 68088886AA or equivalent
• Axle nut cotter pins × 2 — Use appropriate size for axle nuts
• Drain plug washer × 1 — Use OEM specification

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 front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove both front wheels
6. Place drain pan under front differential
7. Allow differential to cool to safe working temperature if recently driven

Procedure

1. 1

   Drain differential fluid
   Locate the drain plug on the bottom of the differential housing. Using the appropriate socket, remove the drain plug and allow all gear oil to drain completely into the drain pan. Inspect the drained fluid for metal particles or contamination. Remove the differential cover bolts and cover to ensure complete drainage. Clean the cover and housing mating surfaces with a wire brush.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Remove axle shaft nuts
   Remove the cotter pins from both front axle nuts using side cutters or cotter pin removal tool. If nuts are staked instead of pinned, use a punch to unstake. With the vehicle still supported and wheels removed, use a breaker bar and appropriate socket to remove both front axle nuts. These are torqued to 250 Nm and will require significant force. Keep nuts for reference if reusing.
   ⚠Do not allow the axle shaft to fall when nut is removed. The CV joint can be damaged if it drops suddenly.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
3. 3

   Disconnect CV axle shafts from differential
   Access the inner CV joint bolts at the differential flanges. There are typically 6 bolts per side connecting the CV shaft to the differential output flange. Mark the orientation of the CV joint to the flange with a paint marker. Remove all CV bolts from both sides using an Allen key or appropriate socket. Support the axle shafts and carefully pull them away from the differential flanges. Secure axle shafts out of the way using wire or bungee cords to prevent damage.
   Torque spec

   CV Bolts82 Nm (61 lb-ft)
4. 4

   Mark and remove front driveshaft
   Locate the front driveshaft where it connects to the differential input flange (pinion flange). Use a paint marker or scribe to mark the relationship between the driveshaft yoke and the pinion flange for proper reassembly alignment. Remove the four U-joint strap bolts securing the driveshaft to the differential. Support the driveshaft and carefully lower it away from the differential. Secure driveshaft out of the way or remove it completely from the vehicle.
   ℹ️Marking alignment is critical to prevent driveline vibration. Take time to make clear, visible marks on both components.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
5. 5

   Disconnect axle breather and ABS sensors
   Locate the differential breather tube on top of the housing and disconnect it from the breather fitting. Disconnect any ABS wheel speed sensor wiring that may be routed along the differential housing or connected to mounting brackets. Tag all connectors for proper reassembly. Remove any harness mounting clips or brackets attached to the differential.
6. 6

   Remove differential mounting bolts
   Position a transmission jack or differential jack under the center of the differential housing. Raise the jack slightly to take the weight off the mounting bolts but do not lift the differential. Locate all differential mounting bolts that attach the housing to the front axle or crossmember. There are typically 4-6 mounting bolts. Remove all mounting bolts while supporting the differential weight with the jack.
   ⚠️Ensure jack is positioned securely under the differential center before removing mounting bolts. The differential can shift suddenly when the last bolt is removed.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
7. 7

   Remove front differential assembly
   With all mounting bolts removed and the differential supported on the jack, carefully lower the jack while guiding the differential away from the vehicle. Watch for any remaining connections, wiring, or interference with suspension components. The differential will need to be maneuvered around the front axle tubes and suspension. Once clear, roll the jack with the differential out from under the vehicle. If installing a replacement differential, transfer any necessary components (sensors, mounting brackets, breather tube) from the old unit to the new one.
8. 8

   Install differential assembly
   Clean all mounting surfaces on the vehicle where the differential attaches. Position the differential (new or rebuilt) on the transmission jack and carefully raise it into position, maneuvering around suspension components and axle tubes. Align the differential with the mounting holes and thread in all mounting bolts by hand first. Once all bolts are started, torque them to specification in a cross pattern.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
9. 9

   Reconnect driveshaft
   Position the front driveshaft and align the marks made during disassembly on the driveshaft yoke and pinion flange. Install the U-joint strap bolts and tighten evenly in a cross pattern to the specified torque. Verify the driveshaft rotates freely without binding.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
10. 10

    Reconnect CV axle shafts
    Remove wire or supports from the CV axle shafts. Align the marks made during disassembly and guide the inner CV joints onto the differential output flanges. Install all CV bolts for both sides, ensuring proper alignment. Torque CV bolts to specification in a star pattern. Verify both axle shafts are fully seated on the differential flanges.
    Torque spec

    CV Bolts82 Nm (61 lb-ft)
11. 11

    Install differential cover and fill with fluid
    Clean the differential cover and housing mating surfaces thoroughly. Apply a continuous bead of RTV silicone gasket maker to the cover or install a new gasket per manufacturer instructions. Install the cover and torque bolts in a cross pattern to specification. Allow RTV to cure per product instructions if used. Install drain plug with new washer if applicable. Fill differential with 75W-90 GL-5 gear oil through the fill plug opening until oil reaches the bottom of the fill hole (approximately 1.5 quarts). Install fill plug.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect breather and sensors
    Reconnect the differential breather tube to the breather fitting on top of the housing. Reconnect all ABS sensor wiring and secure any wiring harnesses to their original mounting locations using clips and brackets. Ensure no wiring is pinched or routed where it can contact moving components.
13. 13

    Install axle nuts and wheels
    Install both front axle nuts onto the axle shafts. Torque axle nuts to 250 Nm (184 lb-ft). Install new cotter pins through the axle nut castellations and bend pins to secure, or stake the nuts if that is the factory method. Install both front wheels and hand-tighten lug nuts. Lower vehicle until tires just touch the ground. Torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reconnect breather tube and verify it is not kinked or blocked
2. Double-check all mounting bolts, CV bolts, and driveshaft bolts are torqued to specification
3. Verify differential is filled to proper level with correct gear oil
4. Ensure all wiring connectors are properly seated and secured
5. Check for any tools or parts left in the work area before lowering vehicle

Verification

• Start engine and verify no unusual noises from front differential area
• Test 4WD engagement and verify positive engagement with no grinding or binding
• Road test vehicle and verify no vibrations, which would indicate driveshaft misalignment
• Check for leaks around differential cover and axle shaft seals after test drive
• Verify ABS system has no warning lights and wheel speed sensors are functioning
• After 50-100 miles, recheck differential fluid level and inspect for leaks

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