98 Durango 5.2 4x4
I need to replace the bearings and seal on the pinion gear in my 9.25 rear end. I have it all apart and the differential will not come out. What is the problem? What do I do to get this out. I pulled the axles out, removed the two bolts each, on the two "u clamps", holding in the differential. I thought I would just be able to pull the diff out, BUT not that easy. It will come out about 1/2 inch and that's it. Please Help

 

Take pictures!

Did you rotate the pinion gear shaft lock screw to an accessible location on the diff and remove the bolt?


Then you should be able to drop the diff.

 

The pinion is hanging inside the housing. Whenever I move the diff it falls forward. It looks like there is nothing holding it.
Here is what I've done.
I pulled the cover off. Drained fluid. Noticed two nickle size pieces of metal on the magnet and silvery oil coming out. Unscrewed the bolt holding in the pinion shaft. Removed the shaft. Took both c lips out. Pushed the axles out. Reinstalled the shaft and bolt to keep the gears in place.
The diff will move out about a half inch and stop.

 

Sounds like it's still attached to the pinion gear.

Take a look at this:

2002 Durango Service Manual

Download it.

 

Pulled the pinion shaft out again. No help. something is hanging it up. I can push and pull the diff a half inch as hard as I can. Ahrg!!! This can't be that hard. It's on the edge of coming out. I'll check out the download. Thankyou for your help. Anymore ideas will greatly be appreciated.

 

Usually when I have a stuck I wobble the component and feel where the resistance is and go from there. Tap on it with a rubber mallet from the outside.

 

Do I have to move the adjusters out to remove the diff? Feels like its hanging on part of the bearing. I don't know. I can move it out just a bit and the nothing. I have to get this out in order to put bearings on the pinion. HEEELLLPPP

 

Thats what I was getting at. I think you have to use a special tool to back them off from inside the axel housing.

Sorry, I've never pulled one out of these beasts. You can try to contact Parts/Service He knows this ****!

 

ok, I did it!!! There is a hole on either side of the diff housing. Back the adjusters off of the diff. so that the diff comes out. You have to back both sides off. Hold on to it so that it will not fall. It's about 30 pnds. Bearings on the pinion gear were shot. Plan on changing all the bearings and seals. Now the fun part, having bearings pulled, pressed and reinstalling.

 

It might have the limited slip option so if so, remember the friction modifier and I recommend Full Synthetic Mobil One 80-90W gear lube.

Well for never getting into it looks like I called it with the adjusters needing to be backed off. Great to see ya got it. Could you take some pictures please and PM me?