Axle Seal - Front

This procedure replaces the front axle shaft seal on the 2007 Ram 3500 with the AAM 9.25 front axle, requiring removal of the axle shaft and seal replacement.

Warnings

Tools required

Parts

• Front axle shaft seal × 1 — Use OEM specification for AAM 9.25 front axle
• Differential cover gasket × 1 — Use OEM specification
• RTV silicone sealant × 1 — Mopar or equivalent

Fluids

• 75W-90 synthetic gear oil — 3.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove the front wheel on the side being serviced
5. Allow differential to cool if recently driven to avoid burns from hot gear oil

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two caliper slide bolts and hang the caliper from the suspension using wire or a bungee cord. Do not let it hang by the brake hose. Remove the rotor from the hub.
2. 2

   Remove hub bearing assembly
   Remove the three hub bearing retaining bolts accessible from behind the steering knuckle. Carefully pull the hub assembly off the axle shaft. If stuck, tap gently from behind with a soft mallet. Set aside the hub bearing assembly.
3. 3

   Disconnect axle shaft from differential
   Position a drain pan under the axle tube opening. Slide the axle shaft assembly straight out from the axle tube. You may need to rotate the shaft slightly to disengage the inner splines from the differential side gear. Some gear oil may drain from the axle tube opening as the shaft is withdrawn.
4. 4

   Remove old axle seal
   Inspect the axle tube opening and locate the seal positioned inside the tube end. Using a slide hammer with seal puller attachment, hook the old seal and extract it from the axle tube bore. Alternatively, carefully use a punch and hammer to drive the seal inward on one side to tilt it, then pry out with a seal puller. Be careful not to damage the axle tube bore surface.
5. 5

   Clean and inspect axle tube bore
   Thoroughly clean the seal bore area in the axle tube using brake cleaner and shop rags. Use a wire brush to remove any corrosion or debris. Inspect the bore for scoring, pitting, or damage that could prevent proper seal seating or cause premature seal failure. Inspect the axle shaft sealing surface for wear grooves or damage.
6. 6

   Install new axle seal
   Lightly coat the outer diameter of the new seal with gear oil. Apply a thin film of assembly lube or gear oil to the seal lip. Position the seal squarely in the axle tube bore with the seal lip facing inward toward the differential. Using a seal driver or appropriately sized socket that contacts only the outer edge of the seal, drive the seal into the bore until it is fully seated and flush with the axle tube end face.
7. 7

   Reinstall axle shaft
   Lightly coat the axle shaft sealing surface with clean gear oil. Carefully guide the axle shaft through the new seal and into the axle tube, taking care not to damage the seal lip. Rotate the shaft as needed to engage the inner splines with the differential side gear until fully seated. Verify proper engagement per the service manual.ed in the database.
8. 8

   Reinstall hub bearing assembly
   Clean the axle shaft splines and hub bearing bore. Slide the hub bearing assembly onto the axle shaft, ensuring proper engagement. Install the three hub bearing retaining bolts from behind the knuckle and tighten in a star pattern. Verify proper torque specifications from a service manual.
9. 9

   Reinstall brake rotor and caliper
   Install the rotor onto the hub. Position the brake caliper over the rotor and install the caliper slide bolts. Tighten to specification.
10. 10

    Refill front differential
    Check the differential fluid level through the fill plug on the axle housing. Add 75W-90 synthetic GL-5 gear oil as needed until fluid reaches the bottom of the fill plug hole. The front differential capacity is approximately 2.3 quarts total (verify exact capacity in the service manual), but you may not need the full amount depending on how much was lost. Install the fill plug.
11. 11

    Reinstall wheel and lower vehicle
    Install the wheel and tighten lug nuts in a star pattern. Lower the vehicle to the ground and perform final torque on lug nuts to specification (approximately 145 ft-lbs for this vehicle, but verify with service manual).

Reassembly

1. Ensure all fasteners are torqued to proper specifications using a service manual
2. Double-check that the brake caliper is properly secured and brake hose is not twisted
3. Verify the differential is filled to the proper level before driving

Verification

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

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