Hi All, I need to remove my driveshaft from a 2008 Durango Hemi 5.7 4x4. I can’t move it past the cross member. I am considering removing the exhaust down pipe with the hope of being able to move the shaft forward far enough to get it off the spines. Exhaust bolts are thoroughly rusted so will be quite a job therefore I wanted to check if anyone has experience of whether this is the only way? Thanks in advance.

 

I was looking to remove my front shaft for inspection and likely replacement.

What did you find out about how to remove or gain clearance?

 

I got the job done and the front driveshaft / prop shaft replaced! I had to remove the cross member under the transmission for the transfer case shift actuator, so it was already out. I think the cross member being out would be a good idea for just the driveshaft job as well. The driver's side catalytic convertor is one piece from the exhaust manifold and is half the cross over pipe section. It had to come down for clearance to get the front driveshaft off the splines of the transfer case. Remove 2 bolts/flange to the exhaust manifold, unplug both O2 sensors (really tight to get your hands to those wire plugs) and remove the band clamp at the cross over joint directly under the transmission. My clamp was rusted and needed cut off. The clamp is no longer available from Chrysler so I ended up with a stainless 2.25" band clamp from Amazon, they were $16 for a pair. The big thing for the prop shaft is length and it is based on which transfer case you have. Mine was NV244 transfer case at 33.15inch measured as the picture. The NV144 transfer case uses a shorter shaft at 28.74inch and 2WD has No prop shaft.

Overall, a bit more of a challenge than I thought it should or would be. The manifold flange bolts were crusty, the O2 plugs were a pain and it was like a puzzle to get the U-Joint yoke end up and forward enough to get the whole shaft off the transfer case splines. I also had difficulty getting the cross over section of the exhaust to slide back together because of the angle the two pieces needed to mate back up. I ended up with a ratchet strap pulling the passenger's side forward some and a small jack underneath to push it up some to it would line up. That was the part I did the most cussing at. I would recommend getting a new exhaust band clamp and nuts for the manifold flange before beginning. It would also be a good time to replace those two O2 sensors since they will be easily accessible once the catalytic convector is out.

 

Good job and great write up with Good clear pictures. Thanks!!