Front Axle Shafts & Bearings: Installation

Apply RTV sealer to the seal surface of axle shaft housing. Install lip seal on the axle shaft stone shield, with the lip toward the axle spline.
Carefully insert axle shaft into the housing so as not to damage the differential seal at the side gears. Install spindle and brake splash shield. Install 6 new nuts and tighten to specifications. Install the rotor, outer bearing nut, washer and locknut onto spindle. Install brake adapter.
Install inboard brake shoe on adapter. Slowly slide caliper over disc and into adapter. Install anti-rattle springs and retaining clips and torque to specifications. Install wheel and tire and hub dust cover. Test operation.

Slide axle shaft into position. Place bronze spacer on axle shaft with chamfer side facing toward "U" joint. Install spindle, brake adapter and brake splash shield. Tighten nut to 50-70 ft. lbs.
Drive in bearing cups using a suitable installer. Lubricate bearings with suitable lubricant (MOPAR Lubricant Part No. 2525035). Install inner bearing in grease coated hub. Install new seal. Care must be taken not to damage seals.
Install hub and rotor assembly on spindle. Install outer wheel bearing and inner lock nut, tightening to 50 ft. lbs., back off then retighten to 35 ft. lbs. Install outer lock nut and tighten to 65 ft. lbs. Install new gasket on hub, install drive flange lock washers and nuts. Install snap ring and cap in hub, install brake caliper, wheel and tire then lower vehicle.

Inspect the retainer plate and stub shaft for nicks or burrs. Replace if necessary. Install retainer plate and new seal on shaft. Coat oil seal with grease. Place the bearing on the shaft. Use axle bearing replacer (T80T-4000-N), and pinion bearing cone remover (T71P-4621-B) to press bearing onto shaft. A 0.0015" feeler gauge should not fit between the bearing seat and bearing.
Install the stub shaft in the carrier and install 3 retainer bolts. Tighten to 40 ft. lbs. Install right-hand axle shaft assembly into slip yoke. Note the blind spline on the axle shaft assembly. Install splash shield and spindle using new nuts. Tighten to 55 ft. lbs. Install hub and disc assembly. Install caliper and wheel assembly.

Install axle shaft assembly in housing. Care must be taken not to damage seal. Install thrust washer with chamfered end toward slinger on axle. Install spindle. Tighten bolts to 25 ft. lbs. (K10, K1500, K20 and K2500) and to 60 ft. lbs. (K30 and K3500).
Install inner and outer bearing cones in hub using suitable drivers. Lubricate cones and bearings with suitable wheel bearing lubricant. Install inner bearing in cone and install new seal. Install outer bearing and retainer in hub.
Position hub and rotor assembly on spindle. Install inner adjusting nut, tightening to 50 ft. lbs., back off then retighten to 35 ft. lbs. Install outer lock nut and tighten to 65 ft. lbs. Complete reassembly by reversing removal procedure.

Make sure all components are clean. Make sure drive flange bolt and bolt hole threads are clean. Install inner bearing and seal in hub.
Install axle shaft assembly taking care not to damage seal in axle housing. Install spindle and spindle bearing. Install disc brake caliper adapter and splash shield.
Lubricate and install outer bearing in hub assembly. Install hub assembly on spindle. Install washer and adjusting nut and tighten to 50 ft. lbs., then back off 1/6 turn. Install lock washer and lock nut, tightening lock nut to 50 ft. lbs. Bend lockwasher lip over lock nut.
Install drive flange and gasket. Coat drive flange bolts with a suitable Adhesive-Sealant (Locktite 242 or equivalent). Install drive flange bolts.
Install drive flange snap ring in groove at outer end of axle shaft. Install disc brake caliper. Install hub grease cover. Install wheel and tire and lower vehicle.