DRIVELINE/AXLES

Rear Axle - 215RII - Chrysler 300

DESCRIPTION
DESCRIPTION

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Fig. 1: 198/210 Mm Rii Axle Section View
Courtesy of CHRYSLER GROUP, LLC

1 - BEARING, PINION TAIL 6 - DIFFERENTIAL

2 - SHIM, PINION DEPTH 7 - RING, SNAP
3 - BEARING, PINION HEAD 8 - COVER, AXLE
4 - GEAR/SHAFT, PINION 9 - GEAR, RING
5 - BEARING, DIFFERENTIAL SIDE

The 215 MM RII (Rear-Independent-Iron) axle is an independent assembly with a cast iron housing
and differential. The 215 MM RII uses an open differential which is supported by two tapered roller
bearings located on either side of the case. Differential bearing preload and ring gear backlash are
controlled with select snap-rings located on the outside of the differential bearing cups. Pinion height
is set with a select shim located under the rear pinion bearing cup.

AXLE IDENTIFICATION
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Fig. 2: Axle Identification Tag
Courtesy of CHRYSLER GROUP, LLC

The 215 MM axle utilizes a barcoded label which is adhered to the top of the axle housing as shown.
The following information is found on the identification label:

Traceability Code (Plant Use)

Axle Part Number
Axle Gear Ratio

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - AXLE

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth,
tooth contact, worn/damaged gears, or the carrier housing not having the proper offset and
squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific
type of driving condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then
accelerate the vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast
through the peak-noise range. If the noise stops or changes greatly:

Check for insufficient lubricant.

Incorrect ring gear backlash.
 Gear damage.

Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears are unloaded. The side gears are loaded during
vehicle turns. A worn pinion shaft can also cause a snapping or a knocking noise.

BEARING NOISE

The differential and pinion bearings can produce noise when worn or damaged. Bearing noise can be
either a whining, or a growling sound.

Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion
bearing noise will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the
differential. If bearing noise occurs, the rear pinion bearing is the source of the noise. If the bearing
noise is heard during a coast, the front pinion bearing is the source.

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Worn or damaged differential bearings usually produce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differential bearing noise is also constant and varies only
with vehicle speed.

Wheel hub bearings produce noise and vibration when worn or damaged. The noise generally
changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and
to the right. This will load the bearings and change the noise level. Where axle bearing damage is
slight, the noise is usually not noticeable at speeds above 30 mph.

LOW SPEED KNOCK

Low speed knock is generally caused by a worn U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.

VIBRATION

Vibration at the rear of the vehicle is usually caused by a:

Damaged propeller shaft.

Missing propeller shaft balance weight(s).
Worn or out-of-balance wheels.
Loose wheel lug nuts.
Worn U-joints or CV joints.
Loose/broken springs.
Damaged axle shaft bearing(s).
Loose pinion gear nut.
Excessive pinion yoke run out.
Bent halfshaft(s).
Check for loose or damaged front-end components or engine/transmission mounts. These
components can contribute to what appears to be a rear end vibration. Do not overlook engine
accessories, brackets and drive belts.

All driveline components should be examined before starting any repair.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear, can be caused by:

High engine idle speed.

Transmission shift operation.
Loose engine/transmission/transfer case mounts.
Worn U-joints or CV joints.
Worn or broken axle mount isolators.

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Loose pinion gear nut and yoke.
Excessive ring gear backlash.
Excessive side gear to case clearance.

The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the
vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear.
Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.

DIAGNOSTIC CHART
CONDITION POSSIBLE CAUSE CORRECTION
WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel 2. Replace bearing.
bearing.
DIFFERENTIAL CRACKED 1. Improper differential side 1. Replace case and inspect
bearing preload. gears and bearings for further
damage. Set differential
bearing preload properly.
2. Excessive ring gear 2. Replace case and inspect
backlash. gears and bearings for further
damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect
gears and bearings for further
damage. Avoid excessive
vehicle weight.
DIFFERENTIAL GEARS 1. Insufficient lubrication. 1. Replace scored gears. Fill
SCORED differential with the correct fluid
type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
 differential with the proper fluid
type and quantity.
3. Excessive spinning of one 3. Replace scored gears.
wheel/tire. Inspect all gears, pinion bores,
and shaft for damage. Service
as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked axle housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored pinion flange 5. Replace pinion flange and
journal. seal.
6. Axle cover not properly 6. Remove, clean, and re-seal
sealed. cover.

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AXLE OVERHEATING 1. Lubricant level low. 1. Fill differential to correct
level.
2. Improper grade of lubricant. 2. Fill differential with the
correct fluid type and quantity.
3. Bearing preload too high. 3. Readjust bearing pre-load.
4. Insufficient ring gear 4. Re-adjust ring gear
backlash. backlash.
GEAR TEETH BROKE 1. Overloading. 1. Replace gears. Examine
other gears and bearings for
possible damage.
2. Ice-spotted pavement. 2. Replace gears and examine
remaining parts for damage.
3. Improper adjustments. 3. Replace gears and examine
remaining parts for damage.
Ensure ring gear backlash is
correct.
AXLE NOISE 1. Insufficient lubricant. 1. Fill axle with the correct fluid
type and quantity.
2. Improper ring gear and 2. Check ring gear and pinion
pinion adjustment. contact pattern. Adjust
backlash or pinion depth.
3. Unmatched ring gear and 3. Replace gears with a
pinion. matched ring gear and pinion.
4. Worn teeth on ring gear 4. Replace ring gear and
and/or pinion. pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-
load.
6. Loose differential bearings. 6. Adjust differential bearing
preload.
 7. Misaligned or sprung ring 7. Measure ring gear run-out.
gear. Replace components as
necessary.
8. Housing not machined 8. Replace housing.
properly.

STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID DRAIN AND FILL

NOTE: The fluid required for use in this axle is Mopar® Synthetic Gear and Axle
Lubricant 75W-140.

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Fig. 3: Rear Axle Drain Plug
Courtesy of CHRYSLER GROUP, LLC

1. Drive the vehicle until the differential lubricant is at the normal operating temperature.
2. With vehicle in neutral, position and raise vehicle on hoist.
3. Remove rear axle drain plug (1) and drain lubricant completely from the axle.
4. Install drain plug and tighten to 50 N.m (37 ft lbs).
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Fig. 4: Rear Axle Fill Plug
Courtesy of CHRYSLER GROUP, LLC

5. Remove fill plug (1) and fill rear axle with 1.2 L (1.3 qts.) Mopar® Synthetic Gear AND Axle
Lubricant 75W-140 and insure axle is filled to the bottom of the fill hole.
6. Install fill plug and tighten to 50 N.m (37 ft lbs).

REMOVAL
REMOVAL

NOTE: This procedure requires the compression of the rear suspension to ride height.
A drive-on hoist should be used. If a drive-on hoist is not used, screw-style
under-hoist jack stands are required to compress the rear suspension,
facilitating rear halfshaft removal.

CAUTION: Never grasp halfshaft assembly by the inner or outer boots. Doing so may
cause the boot to pucker or crease, reducing the service life of the boot
and joint. Avoid over angulating or stroking the C/V joints when handling
the halfshaft.
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Fig. 5: Rear Axle Drain Plug
Courtesy of CHRYSLER GROUP, LLC

1. With vehicle in neutral, position and raise vehicle on hoist.

2. Using 14mm hex, remove axle drain plug (1) and drain rear axle fluid into container suitable for
fluid reuse.
3. Install drain plug (1) and torque to 50 N.m (37 ft. lbs.) torque.

Fig. 6: Identifying Clamps & Rear Exhaust System

Courtesy of CHRYSLER GROUP, LLC

4. Remove rear exhaust system (2) on dual-outlet exhaust models, otherwise, lower exhaust
system at rear hanger(s).
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Fig. 7: Alignment Marks AT Shaft And Flange
Courtesy of CHRYSLER GROUP, LLC

5. Apply alignment index marks (3) to the propeller shaft rubber coupler (1) and axle flange (2).

Fig. 8: Propeller Shaft AT Rear Axle Flange

Courtesy of CHRYSLER GROUP, LLC

6. Remove three propeller shaft coupler (1)-to-axle flange (2) bolt/nuts.

 Fig. 9: Halfshaft Removal (V6 Models)

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Courtesy of CHRYSLER GROUP, LLC

7. Using suitable screwdriver (1), partially disengage halfshaft(s) (2) from axle assembly.

Fig. 10: Supporting Rear Axle With Jack Stands Transmission Jack
Courtesy of CHRYSLER GROUP, LLC

8. If a drive-on hoist is used, position transmission jack (1) to rear axle assembly. If a drive-on
hoist is not used, compress rear suspension using screw-style under-hoist jack stands (2), then
position transmission jack to rear axle assembly.
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Fig. 11: Rear Axle Forward Mount Isolator & Bolt/Nut
Courtesy of CHRYSLER GROUP, LLC

9. Remove rear axle forward mount isolator (1) bolt/nut (2).

10. Remove two rear axle-to-crossmember bolts (1).

Fig. 12: Propeller Shaft Supported

Courtesy of CHRYSLER GROUP, LLC

11. Carefully lower rear axle. While lowering axle, separate propeller shaft from axle and support
with suitable rope or wire (1).
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Fig. 13: Halfshaft Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

12. Lower axle just enough to remove both halfshafts one at a time. Shift axle assembly in one
direction, compressing one halfshaft while removing the other (1). Use caution to protect axle
seal and journal.
13. Remove axle assembly from vehicle and transfer to bench.

INSTALLATION
INSTALLATION

Fig. 14: Axle Seal Installation

Courtesy of CHRYSLER GROUP, LLC

1. Install new axle seal(s) (1) using (special tool #9755, Installer, Seal) (2).

NOTE: Always use (special tool #9099, Seal Protector, Differential Output) when
installing half shaft into the transaxle. If the Seal Protector is new please
split at seam before using.

NOTE: Use care when installing halfshaft to axle assembly. The halfshaft
installation angle should be minimized to avoid damage to seal upon
installation.

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Fig. 15: Identifying Rear Axle, Rear Driveshaft, Rear Axle Flange, and Halfshafts
Courtesy of CHRYSLER GROUP, LLC

NOTE: While raising rear axle reposition rear drive shaft to rear axle flange.

2. Install new circlip(s), on halfshafts (3).

3. Raise axle just enough to install both halfshafts one at a time. Be careful not to damage axle
seals using (special tool #9099, Seal Protector, Differential Output) (1). Shift axle assembly in
one direction, compressing one halfshaft while installing the other.
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Fig. 16: Halfshaft Removal/Installation
Courtesy of CHRYSLER GROUP, LLC

NOTE: Use care when installing halfshaft to axle assembly. The halfshaft
installation angle should be minimized to avoid damage to seal upon
installation.

4. Using new circlip(s), install halfshaft (1) to rear axle assembly. Use care not to damage axle
seals (2). Verify proper installation by pulling outward on joint by hand.

Fig. 17: Alignment Marks AT Shaft And Flange

Courtesy of CHRYSLER GROUP, LLC
5. Raise rear axle assembly into position. Align propeller shaft index marks (3) and start propeller
shaft coupler-to-axle bolt/nuts by hand.

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Fig. 18: Rear Axle Forward Mount Isolator & Bolt/Nut
Courtesy of CHRYSLER GROUP, LLC

6. Install two rear axle-to-crossmember bolts (1) and torque to 220 N.m (162 ft. lbs.).
7. Install rear axle front mount isolator (1) as shown and torque bolt/nut to 65 N.m (48 ft. lbs.).

Fig. 19: Supporting Rear Axle With Jack Stands Transmission Jack
Courtesy of CHRYSLER GROUP, LLC

8. Again verify halfshaft inner joints are fully engaged to axle assembly.
 9. Remove transmission jack (1).
10. If used, remove screw-type under-hoist jack stands (2).

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Fig. 20: Propeller Shaft AT Rear Axle Flange
Courtesy of CHRYSLER GROUP, LLC

11. Torque propeller shaft coupler-to-axle flange bolt/nuts to 58 N.m (43 ft. lbs.).

SPECIAL TOOLS
SPECIAL TOOLS

1026 - Puller
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC.)
6448A - Installer, Bearing/Gear
(Originally Shipped In Kit Number(s) 6947, 8667, 8837, 8867.)
9099 - Seal Protector, Differential Output
(Originally Shipped In Kit Number(s) 9324, 9324CC.)
9754 - Installer, Seal
(Originally Shipped In Kit Number(s) 9750.)
9755 - Installer, Seal
(Originally Shipped In Kit Number(s) 9750.)
C-3281 - Holder, Flange
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)

SEAL, AXLE DRIVE SHAFT

REMOVAL
REMOVAL

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Fig. 21: Remove Lside Seal
Courtesy of CHRYSLER GROUP, LLC

1. Remove halfshaft(s). Refer to REMOVAL and REMOVAL .

2. Using suitable screwdriver (1), remove axle shaft seal (2).
3. Visually inspect halfshaft seal journal for damage (excessive seal groove, nicks, scratches,
etc.). Replace halfshaft if necessary.

INSTALLATION

INSTALLATION
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Fig. 22: Axle Seal Installation
Courtesy of CHRYSLER GROUP, LLC

1. Using Installer (special tool #9755, Installer, Seal) (2), install NEW axle shaft seal (1). Lubricate
the inside diameter with Mopar® Gear and Axle Lubricant 75W-140 to protect seal during
halfshaft installation.
2. Install halfshaft(s). Refer to INSTALLATION and INSTALLATION .

Fig. 23: Rear Axle Fill Plug

Courtesy of CHRYSLER GROUP, LLC

3. Remove fill plug (1) to check and adjust rear axle fluid level. Top off axle with Mopar® Gear and
Axle Lubricant 75W-140. Reinstall fill plug and torque to 50 N.m (37 ft. lbs.) torque.
SEAL, DRIVE PINION
REMOVAL

REMOVAL

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Fig. 24: Measuring Turning Torque
Courtesy of CHRYSLER GROUP, LLC

1. Remove rear axle assembly from vehicle. Refer to Rear Axle Removal.
2. Measure axle assembly rotating torque and record measurement for reuse on assembly.

Fig. 25: Pinion Flange Nut Removal/Installation

 Courtesy of CHRYSLER GROUP, LLC

3. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1) and 41mm socket, remove
pinion flange nut and discard.

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Fig. 26: Removing Pinion Flange With Puller 1026
Courtesy of CHRYSLER GROUP, LLC

NOTE: Due to axle imbalance concerns, it is necessary to make sure pinion

flange-to-shaft orientation is maintained. If alignment marks are not
visible, apply appropriate marks before removing pinion flange.

4. Using Puller (special tool #1026, Puller) (1), remove pinion flange (2) from pinion shaft.
 Fig. 27: Pinion Seal Removal
Courtesy of CHRYSLER GROUP, LLC

5. Using suitable tool (1), remove pinion seal (2) and discard.

INSTALLATION

INSTALLATION

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Fig. 28: Installing Pinion Seal
Courtesy of CHRYSLER GROUP, LLC

1. Apply light coating of gear lubricant to the lip of the pinion seal.
2. Using Installer (special tool #9754, Installer, Seal) (1), install pinion seal until tool bottoms on
carrier.
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Fig. 29: Pinion Flange Installation
Courtesy of CHRYSLER GROUP, LLC

3. Install pinion flange into position. Align index marks to maintain assembly balance.
4. Using Installer (special tool #6448A, Installer, Bearing/Gear) (1), lightly tap on pinion flange (2)
until adequate pinion shaft threads are exposed.

Fig. 30: Pinion Flange Nut Removal

Courtesy of CHRYSLER GROUP, LLC

5. Install new pinion flange nut. Using Flange Wrench (special tool #C-3281, Holder, Flange) (1)
and 41mm socket, torque nut to 136 N.m (100 ft. lbs.).
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Fig. 31: Measuring Rotating Torque
Courtesy of CHRYSLER GROUP, LLC

6. Measure assembly turning torque. Axle assembly rotating torque must be should be equal to
the reading recorded upon seal/flange removal.

Fig. 32: Pinion Flange Nut Removal

Courtesy of CHRYSLER GROUP, LLC

7. If rotating torque is low, increase pinion flange nut torque in 7 N.m (5 ft. lbs.) increments. Repeat
until proper rotating torque is received.
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Fig. 33: Staking Pinion Flange Nut
Courtesy of CHRYSLER GROUP, LLC

8. Stake pinion flange nut (1) as shown.

9. Install rear axle assembly. Refer to Rear Axle Installation.