My rear axle just went south. The pinion nut came off while driving and tore up my ring gear. I am looking for some info regarding rebuilding a 9.5 rear. I have seen people here on the forum talk about a post a while back called rear axle failure, I have not been able to find it and that it goes through the entire rebuild process, but I haven't been able to find it. Any help would be great, any info regarding backlash and pinion depth would be helpful.
Thanks in advance.

Mike-

 

If your going to try and rebuild the same axle then the Dodge service manual would be the absolute best book to have. It is very expensive and a migraine's worth of procedures. I put new pinion bearings and diff. side bearings on my dana60 6 months ago and it cost me about $800 in parts from the dodge house. You could prob cut down the cost alot through aftermarket, I just didn't want to chance getting chinky parts. For pinion to ring gear depth you will need either prussion blue gear paint (NAPA) or some other gear paint and a pinion and diff side gear shim kit. You put the gear paint in three or four location on the ring gear (cover prob 4 teeth per location) and then rotate the assembly. The gear paint will show how the pinion teeth is hitting the ring gear and depending on how this looks will depend on whether you add a shim to the pinion or to the side bearings. The service manual goes through this pretty extensively, too bad it is a tad expensive.

 

Rebuilding a Corporate 9.25" axle: http://dodge.off-road.com/dodge/arti....jsp?id=194353

 

Instead of rebuilding the troublesome 9.25 differential
consider replacing it
with either:

Dana 60
GM 12 bolt
Ford 9 inch
QuickChange
or the aluminum case Mopar Performance catalog model

 

Do they make a D60 with 5 lug axles ... or rather ... do they make 5 lug axles for the D60?

 

Had the same thing happen last summer, went with a Jasper refurbished rear-end - basically it was the whole axel but carried a 3 year warranty. It was expensive, very expensive.

 

What do you call "very expensive" ... and did you do the install yourself?

 

There are 5 lug Dana 60s from the factory on
International Scouts 1961-1980
and 1963-1973 Jeep J series 3/4 ton pickups
and maybe others.

Aftermarket axle companies like Moser in the east and Dynatrac in the west can make these axles.

 

go to the junk yard and pick up a 1500 axle.. i lucked out with my old truck and got a new axle for 150 bucks off my friends dad who was using the truck for parts

 

You'll just need the ring and pinion, and a master rebuild kit. I doubt the carrier is shot.