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

Warnings

Tools required

Parts

• Rear differential assembly (if replacing complete unit) × 1 — Use OEM specification for AAM 11.5 inch axle
• Differential cover gasket × 1 — Use OEM specification or RTV silicone
• Differential mounting hardware kit × 1 — May be included with new differential
• New cotter pins for axle nuts × 2 — OEM specification
• Driveshaft u-joint strap bolts × 4 — Replace if corroded

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. Allow differential to cool if vehicle was recently driven
4. Raise rear of vehicle and support with jack stands on frame rails behind rear axle
5. Remove both rear wheels
6. Spray all fasteners with penetrating oil and allow 15-20 minutes to soak
7. Position transmission jack under differential housing center section

Procedure

1. 1

   Drain differential fluid
   Place drain pan under differential cover. Remove all differential cover bolts and carefully pry cover loose using a pry bar. Allow all gear oil to drain completely into pan. Clean cover and mounting surface with wire brush and solvent. Inspect drained fluid for metal particles or debris indicating internal damage.
   Torque spec

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

   Mark and remove driveshaft
   Mark the driveshaft and differential pinion flange alignment with paint or chalk for proper reassembly orientation. Remove the four u-joint strap bolts connecting the rear driveshaft to the differential pinion flange. Support driveshaft and slide it rearward off the pinion yoke. Secure driveshaft out of the way or remove completely. Cover pinion opening with a plastic bag to prevent contamination.
   ⚠Mark driveshaft orientation before removal. Improper alignment during reinstallation can cause driveline vibration.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Disconnect axle shafts from differential (if equipped with CV axles)
   If vehicle has independent rear suspension or CV-equipped axles, remove the CV bolts connecting inner CV joints to differential output flanges on both sides. If vehicle has solid axle with semi-floating axles, proceed to remove axle nuts at wheel hubs. Remove cotter pins and loosen axle nuts using a breaker bar. Support axle shafts to prevent damage.
   ℹ️Ram 2500 typically uses solid axle configuration. CV bolts apply only if aftermarket independent rear suspension is installed.
   Torque spec

   CV Bolts82 Nm (61 lb-ft)

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Disconnect brake components and sensors
   Disconnect the rear wheel speed sensors from both sides by unplugging electrical connectors. Disconnect brake line brackets from differential housing or axle tubes using appropriate socket. Do not disconnect brake lines themselves unless necessary. Disconnect parking brake cables from mounting points on differential or axle housing. Label all connections for proper reassembly.
5. 5

   Remove shock absorbers lower mounts
   Remove lower shock absorber mounting bolts on both sides where they connect to axle housing or differential mounting brackets. Allow shocks to hang freely. This provides clearance for differential removal. Note orientation of any washers or spacers.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
6. 6

   Disconnect track bar and sway bar links
   Remove track bar mounting bolt where it connects to rear axle housing on driver side. Remove sway bar link bolts on both sides connecting sway bar to axle housing. Support components to prevent them from hanging by rubber bushings.
   Torque spec

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

   Support and disconnect leaf springs
   Ensure transmission jack is securely positioned under differential center section and properly supporting full weight. Remove u-bolt nuts on both sides securing axle housing to leaf springs. There are typically four u-bolts total (two per side). Carefully lower transmission jack to separate differential assembly from leaf springs. Lower slowly and watch for any remaining connections.
   ⚠️Differential assembly will become free once u-bolts are removed. Ensure transmission jack is securely supporting the full weight before removing final fasteners.
8. 8

   Remove differential assembly
   With all connections disconnected and u-bolts removed, carefully lower differential assembly using transmission jack. Have an assistant guide axle tubes and watch for any snagged lines or sensors. Lower unit completely and roll transmission jack out from under vehicle. If replacing complete assembly, transfer any reusable components like brake backing plates or brackets to new differential.
   ⚠Rear differential assembly weighs approximately 150-200 lbs. Use proper lifting technique and have assistance available.
9. 9

   Prepare new differential assembly
   Clean all mounting surfaces on new differential housing. Install any transferred components such as brake backing plates, wheel speed sensor brackets, or shock mounting brackets to new differential. Verify all studs and mounting points are clean and free of debris. Apply light coat of anti-seize to u-bolt threads. If differential came without gear oil, fill through fill plug to proper level with Mopar 75W-140 Synthetic Gear Lubricant.
10. 10

    Install differential assembly
    Position new differential assembly on transmission jack and carefully raise into position under vehicle. Align axle spring perches with leaf springs. Have assistant guide assembly into place. Raise until spring perches are fully seated on leaf springs. Install u-bolts over axle tubes and through leaf spring plates. Thread nuts onto u-bolts hand-tight initially.
11. 11

    Reconnect suspension and chassis components
    Reinstall track bar mounting bolt to differential housing on driver side. Reconnect sway bar links to both sides of axle housing. Reinstall lower shock absorber mounting bolts on both sides. Torque all mounting bolts to specification. Torque u-bolt nuts in cross pattern to manufacturer specification (typically 120-180 Nm but verify with service manual as not provided in torque list).
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
12. 12

    Reconnect brake components and sensors
    Reconnect parking brake cables to mounting points on differential or axle housing. Reattach brake line brackets to differential housing using mounting bolts. Reconnect rear wheel speed sensors on both sides by plugging in electrical connectors. Ensure all wiring is properly routed and secured away from moving components.
13. 13

    Reconnect axle shafts
    If vehicle has CV-equipped axles, align inner CV joints with differential output flanges and install CV bolts. If vehicle has solid axle with semi-floating axles, ensure axle shafts are fully seated in differential and install new axle nuts at wheel hubs. Torque axle nuts to specification and install new cotter pins. Torque CV bolts if applicable.
    ℹ️Always use new cotter pins on axle nuts. Bend tabs properly to prevent loosening.
    Torque spec

    CV Bolts82 Nm (61 lb-ft)

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Reinstall driveshaft
    Align driveshaft with pinion flange using alignment marks made during removal. Install u-joint straps and bolts. Tighten strap bolts evenly in cross pattern to prevent binding. Torque all four u-joint strap bolts to specification.
    ⚠Verify alignment marks match. Improper driveshaft phasing causes vibration and premature wear.
    Torque spec

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

    Install differential cover and fill with fluid
    Clean differential cover and housing mating surface thoroughly. Apply new gasket or RTV silicone bead (1/8 inch) around cover perimeter. Install cover and differential cover bolts. Torque bolts in cross pattern to specification. Allow RTV to cure per manufacturer instructions if used. Remove fill plug and add Mopar 75W-140 Synthetic Gear Lubricant until fluid reaches bottom of fill hole (approximately 2 quarts). Reinstall fill plug.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
16. 16

    Reinstall wheels and lower vehicle
    Install both rear wheels. Thread lug nuts by hand to prevent cross-threading. Torque wheel lug nuts in star pattern to specification. Lower vehicle from jack stands. With vehicle on ground, re-torque lug nuts in star pattern to final specification.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Check differential fluid level after 50-100 miles of driving and top off if necessary
3. Inspect for leaks around differential cover and pinion seal after test drive
4. Verify all electrical connections for wheel speed sensors are secure

Verification

• Test drive vehicle at various speeds and verify no abnormal vibrations or noises from differential
• Verify all gears engage properly including reverse
• Check for fluid leaks around differential cover and pinion seal
• Verify parking brake operates correctly
• Verify ABS warning light does not illuminate (indicates proper wheel speed sensor connection)
• Listen for proper gear mesh sound during acceleration and deceleration - no whining or grinding noises
• After 50-100 miles, recheck all mounting bolts and u-bolt torque specifications

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