Bric Rods » Dana http://bricrods.com Real Automobile Work With a Twist Wed, 20 Oct 2010 17:45:08 +0000 http://wordpress.org/?v=2.9.1 en hourly 1 Dana Disassembly http://bricrods.com/2009/10/dana-disassembly/ http://bricrods.com/2009/10/dana-disassembly/#comments Tue, 06 Oct 2009 14:40:50 +0000 bric http://bricrods.com/?p=192 Today’s topic differs from some of the more ‘old school’ topics normally covered, but most of the information herein can be transferred to most Dana assemblies. The 9.25″ rear differential used in 90’s era Dodge trucks has a basic assembly, though it can prove difficult to remove. What goes wrong with these differentials is housed in the center section, among the shims used to correctly space the limited slip gears. One of these shims on each side is load bearing – taking the majority of side loads incurred from cornering forces, otherwise known as lateral movement. These then wear and crack, sending little pieces of shrapnel throughout the assembly. Luckily there is a magnet to catch most of this, however, the longer this continues, the worse the damage.
That said, to disassemble, one must remove the cover plate, remove the rear wheels and brakes (for ease of removal, though this can be done without the removal of the brakes), and remove the retaining pin in the center of the housing. Once this pin is removed, push either axle inward, remove the C-clip, and pull the axle out; repeat this process for the other axle. once these are removed, one can attempt to remove the differential assembly simply by pulling it out. If it does not come out easily, one must turn the adjusting collars in either axle, which necessitates a special hex tool. Once it is all removed, it is a simple matter of replacing the shims (which are not just shims, but that’s another matter) and reversing the same steps to reassemble the rear end. Don’t forget to fill the case with gear oil though, or you’re back at it shortly.

MB

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