CV Axle - Rear

This procedure covers the removal and replacement of the rear CV axle shaft assembly on a 4WD 2007 Ram 3500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Rear CV axle shaft assembly × 1 — Use OEM specification for AAM 11.5 inch or AAM 10.5 inch rear axle
• Axle hub nut × 1 — Replace if damaged during removal
• Differential cover gasket × 1 — Use OEM specification

Fluids

• 75W-90 synthetic gear oil — 5.5 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 (1/2 turn)
4. Raise rear of vehicle and support on jack stands positioned on frame rails
5. Remove rear wheels completely
6. Identify which CV axle requires replacement (driver or passenger side)

Procedure

1. 1

   Remove axle hub nut
   This vehicle uses a full-floating rear axle (AAM 11.5). There is NO center axle hub nut. The axle shaft is retained by a bolted flange at the outer end of the hub. Remove the axle shaft flange bolts (typically 8 bolts) to free the shaft; the wheel bearings are retained by adjustable spindle nuts, not a single center hub nut.
2. 2

   Remove brake caliper and rotor
   Remove the two caliper mounting bracket bolts using appropriate socket. Support the caliper with wire or bungee cord - do not let it hang by the brake hose. Remove the brake rotor by pulling it straight off the hub. If rotor is stuck, use penetrating oil and strike from behind with a rubber mallet.
3. 3

   Remove ABS sensor if equipped
   If the vehicle has ABS, locate the wheel speed sensor mounted to the axle tube or backing plate. Disconnect the electrical connector and remove the sensor mounting bolt. Carefully pull the sensor out to prevent damage. Set aside in safe location away from debris.
4. 4

   Mark differential cover position
   Before removing the differential cover, use a marker or scribe to mark the cover position relative to the housing. This will help with proper reinstallation. Position drain pan underneath differential.
5. 5

   Remove differential cover
   Remove all differential cover bolts working in a cross pattern. Start by loosening the top bolts first, then loosen bottom bolts gradually to allow controlled draining of gear oil into the drain pan. Once oil has drained, remove cover completely and scrape old gasket material from both cover and housing using wire brush and scraper.
6. 6

   Access CV axle inner retention
   The full-floating AAM 11.5 axle shaft is NOT retained by an internal C-clip. Once the outer axle flange bolts are removed, the solid axle shaft slides straight out of the axle tube. Differential cover removal is not required to remove a full-floating axle shaft.
7. 7

   Remove CV axle inner retention clip
   N/A — Full-floating AAM 11.5 axles do not use C-clip retention. Skip this step; the shaft is removed via the outer bolted flange only.
8. 8

   Remove CV axle assembly from hub
   After removing the axle flange bolts, pull the solid axle shaft straight out of the axle tube. It should slide out by hand or with a slide hammer bolted to the flange if seized. There is no CV joint; the shaft simply disengages from the differential side gear splines.
9. 9

   Inspect components
   With the axle removed, inspect the hub bearing for roughness or play, check differential side gear splines for wear or damage, and examine the axle tube seal. Replace any worn components as needed. Clean all mating surfaces thoroughly with solvent and lint-free cloth.
10. 10

    Install new CV axle assembly
    Carefully guide the new CV axle shaft into position, inserting the inner CV joint into the differential housing first. Align the splines with the side gear and push inward until the shaft is fully seated. Then align the outer CV joint splines with the hub and push the axle through until it seats in the hub bearing.
11. 11

    Install inner retention clip
    From inside the differential housing, install a new or reused C-clip or snap ring onto the inner CV axle shaft groove. Ensure the clip is fully seated in its groove and properly retains the axle to the side gear. Pull outward on the axle from outside to verify it is locked in place.
12. 12

    Reinstall differential cover
    The AAM 11.5 uses RTV silicone sealant (not a paper gasket) on the cover. Apply a continuous bead of RTV, position the cover using alignment marks, and torque the cover bolts in a cross pattern to approximately 30 ft-lbs.
13. 13

    Refill differential with gear oil
    Locate the differential fill plug on the front or side of the housing. Remove the fill plug and add 75W-140 synthetic gear oil (verify grade for your axle) until it reaches the bottom of the fill hole (oil should just begin to seep out). Add limited-slip friction modifier if equipped with a limited-slip differential. Install fill plug securely. Total capacity is approximately 3.6 quarts but fill to proper level, not by quantity.
14. 14

    Reinstall hub components
    Reinstall the ABS sensor if equipped, ensuring it is properly seated and connector is secure. Install the brake rotor onto the hub. Reinstall the brake caliper and mounting bracket, tightening caliper bracket bolts securely.
15. 15

    Install and torque axle hub nut
    Reinstall the axle shaft and torque the axle flange bolts to specification (approximately 30-40 ft-lbs in a cross pattern). If wheel bearings were disturbed, set spindle nut preload per the AAM full-floating adjustment procedure — do NOT torque to 200+ ft-lbs.

Reassembly

1. Reinstall wheels and hand-tighten lug nuts in star pattern
2. Lower vehicle to ground and torque wheel lug nuts to specification in star pattern
3. Remove wheel chocks and verify parking brake releases properly
4. Check for any gear oil leaks around differential cover after initial startup

Verification

• Start engine and verify no unusual noises from rear axle
• Drive vehicle forward and reverse slowly to verify axle engagement
• Test drive vehicle at various speeds and verify no vibration, clicking, or binding from CV axle
• Verify ABS system functions properly if equipped (check for warning lights)
• Recheck differential oil level after test drive and top off if necessary
• Inspect differential cover for leaks after 50-100 miles of driving

More procedures for this vehicle