Driveshaft - Rear

This procedure covers the removal and installation of the rear driveshaft on a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine, including U-joint and flange connections at the transfer case and rear differential.

Warnings

Tools required

Parts

• Rear driveshaft assembly × 1 — Use OEM or quality aftermarket replacement
• Differential pinion yoke nut × 1 — Use new nut - not reusable
• U-joint strap bolts (if replacing) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks at front wheels to prevent vehicle movement
3. Raise rear of vehicle using floor jack at rear axle or frame rail
4. Support vehicle on jack stands placed at frame rails behind transfer case
5. Ensure adequate clearance to work under vehicle comfortably
6. Place transmission in neutral to allow driveshaft rotation for access to fasteners

Procedure

1. 1

   Mark driveshaft orientation
   Use center punch or paint marker to mark the relationship between the rear driveshaft flange and the pinion yoke on the differential. Also mark the front driveshaft flange to the transfer case output flange. These marks ensure proper phasing during reinstallation to prevent vibration.
2. 2

   Disconnect rear U-joint or flange
   At the rear differential pinion yoke, remove the four U-joint strap bolts (two straps, two bolts each) connecting the driveshaft U-joint to the pinion yoke. Remove the bolts and straps, then carefully support the U-joint caps so they do not fall off the trunnions. Rotate driveshaft as needed to access all fasteners. Support the rear of the driveshaft to prevent it from dropping.
   Torque spec

   U-Joint Strap Bolts35 Nm (26 lb-ft)

   Driveshaft Flange Bolts75 Nm (55 lb-ft)
3. 3

   Support and separate rear connection
   With an assistant or using a transmission jack, support the weight of the driveshaft. Carefully pry or pull the rear U-joint or flange away from the pinion yoke. The driveshaft will now be hanging from the front connection only. Be careful not to let it bind or hang at an extreme angle.
4. 4

   Disconnect front flange connection
   At the transfer case output, remove the four bolts securing the front driveshaft flange to the transfer case output flange. Rotate the driveshaft to access all four bolts. Keep track of any washers or spacers.
   Torque spec

   Driveshaft Flange Bolts75 Nm (55 lb-ft)
5. 5

   Remove driveshaft assembly
   Carefully lower and slide the driveshaft rearward to clear the transfer case output flange, then remove it from under the vehicle. The driveshaft is heavy and awkward, use caution. Place driveshaft on a clean work surface. If only replacing the driveshaft and not servicing the differential, proceed to installation.
6. 6

   Inspect components
   Inspect the pinion yoke, transfer case output flange, U-joints, and flange connections for wear, damage, or looseness. Check for leaking seals at the pinion or transfer case. Clean all mounting surfaces with a wire brush and shop rags. If U-joints show wear or binding, they should be replaced before reinstallation.
7. 7

   Install driveshaft to transfer case
   Lift the driveshaft into position, aligning the front flange with the transfer case output flange according to the alignment marks made during disassembly. Start all four bolts by hand to ensure proper thread engagement. Verify alignment marks match before tightening.
   Torque spec

   Driveshaft Flange Bolts75 Nm (55 lb-ft)
8. 8

   Torque front flange bolts
   Tighten the transfer case output flange bolts in a criss-cross pattern to the factory-specified torque (verify in service manual). Rotate the driveshaft to access each bolt position. Rotate the driveshaft to access each bolt position. Verify all bolts are properly seated and torqued.
   Torque spec

   Driveshaft Flange Bolts75 Nm (55 lb-ft)
9. 9

   Connect rear U-joint or flange
   Support the rear of the driveshaft and align the rear U-joint or flange with the pinion yoke according to the alignment marks. Ensure proper phasing by matching your marks exactly. If equipped with U-joint straps, position the U-joint caps in the yoke and install straps. If equipped with a flange, align bolt holes and start all bolts by hand.
10. 10

    Install and torque rear fasteners
    If equipped with U-joint straps, apply medium-strength thread locker to the strap bolt threads and torque to the factory-specified value (verify in service manual, typically approximately 19-22 Nm / 14-16 lb-ft) in a criss-cross pattern. If equipped with a flange connection, torque the flange bolts to the factory-specified value (verify in service manual) in a criss-cross pattern. Rotate driveshaft as needed to access all fasteners.
    Torque spec

    U-Joint Strap Bolts35 Nm (26 lb-ft)

    Driveshaft Flange Bolts75 Nm (55 lb-ft)
11. 11

    Check clearances and rotation
    Manually rotate the driveshaft through several complete revolutions to ensure it rotates freely without binding or contacting any components (exhaust, frame, fuel tank skid plate, etc.). Verify minimum 1 inch clearance to all components. Check that all fasteners are tight and properly torqued.

Reassembly

1. Ensure all alignment marks were matched during installation to maintain proper driveshaft phasing
2. Verify all fasteners are torqued to specification and thread locker was applied where specified
3. Double-check that driveshaft has adequate clearance to all surrounding components

Verification

• Remove jack stands and carefully lower vehicle to the ground
• Start engine and shift through all transmission gears while stationary to verify driveshaft rotation
• Test drive vehicle at various speeds (15-70 mph) and listen for any unusual vibrations, clunks, or noises
• Any vibration at highway speeds indicates improper phasing or balance - recheck alignment marks
• After test drive, re-inspect all fasteners for proper torque and check for any fluid leaks at pinion or transfer case seals

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