Chrysler 9.25 Diff: COMPLETE Step by Step Rebuild and Install!!

Come along with me while I investigate a differential Whine, and install some 4:56 gears in the process! Completely rebuild the differential along with new clutch packs, then the proper way to install a diff into the housing. This is a major job not for the faint of heart, so be ready to get dirt, and frustrated along the way.
Thanks for watching, I hope you enjoy it and learn something!
Here's the link for the Bearing Adjustment Tool:
a.co/d/fkkY0r8

[@spelunkerd]

Probably the best summary of this procedure I've ever found here on the 'net. I get a feeling that many pros cut a few corners to save time when doing this job. You didn't. You might have come across my videos of clutch pack replacement for this differential in the past. You've raised the bar, for sure, and you gained another subscriber today.

[@Dartmech]

Thank you for the kind words! I appreciate them!

[@scottwitherow7586]

Excellent video! I've got mine all torn down and ready for assembly - and you filled in some things that "I didn't know that I didn't know."

[@Dartmech]

Great to hear!

[@davidhendry5951]

This is a kick ass video. You have got to have your balls screwed on pretty tight to follow it because he doesn't waste any time, but I honestly wouldn't want it any other way ( just rewind 50 times, that's fine). I did this procedure 10 yrs. ago or so with my 9.25 dodge and it lasted pretty good but... she's whining again. I have it torn down a little and looking at the open diff wondering what I did then, soooo.... looking for video to basically revive my memory (71 yrs. old). I think this video will do just that, THANK YOU !!!!!

[@Moparmaga-1]

Ive done this before on my Dakota r/t years ago. This is a great video. I didn't have a video to reference.

[@royalchiefindian]

AMAZING!!! I just bought some Yukon lsd gears, asked for instructions said “KZbin how to cut thick gear👨🏻‍💻”. Bro you’re Goated !!!

[@gregoryking9348]

I did some of that on my '03 Dakota QC 4x4 a week ago. I didn't replace any bearings and races, ring and pinion (it's a 3.55), crush sleeve - just the clutch packs and tube seals. I WANTED to do a full rebuild but 2 things made that decision for me. First is $, the second is I live in SE Wisconsin and the horrible body panel and cabin rust/rot would be throwing good money after a bad cause. Although I found some useful video's, and one best one of them all to prepare me for the project I'm feeling cheated by the KZbin search engine that yours wasn't in the top 50 given to me. It's only now, about 2 weeks since the job was done that your video thumbnail/preview was on the scroll-down panel while I was goofing around looking at random assorted video topics. Unfortunate because yours is the best one of the 50 or so I previewed. 👍🏻

[@Dartmech]

Wow, thank you for those kind words! I wish you’d been able to see it sooner too, but I appreciate you taking the time to reach out!

[@donryan3427]

Thank you for your tutorial , i feel confident enough to ATTACK my 2014 Ram .... had a bearing whining since some time , changed my outer wheel bearings , hoping that was the issue ... but no :-( again thank you for your clear and concise explanation !! :-) keep up the nice work my friend !!

[@timwatson559]

Next time, measure the depth requirement for the axle shaft into the carrier assembly. then bind the axle into a vise. Now install the carrier assembly so that the splines align and slide the axle shaft into the spider gear and then just turn the carrier and spin the spider gears as you want.

[@alanstrain801]

This is an awesome video and THANK YOU SO MUCH FOR THE DETAILED DESCRIPTION!!

[@Dartmech]

Glad it was helpful!

[@wnwanted94]

I bought some 4.56 gears years ago… still haven’t installed them because I know my truck will be on the lift for a month while I figure out my pinion depth and all those measurements lol! I think this video went a little too quickly for a beginner but I appreciate it! I was also thinking about installing a Detroit locker at the same time. But they’re pretty pricey.

[@Dartmech]

Thanks for the feedback! There's a fine line between boring and informative, and it's hard to hit sometimes haha. It wasn't terrible, but definitely a project.

[@mackredenbarger]

@@DartmechI have a good friend who has set up many axles before and is a master Volvo semi tech helping me come Wednesday to do this. I am however going to use the factory pinion bearings to use as “tester bearings” or just start out with factory shim. Unfortunately I couldn’t get two bearings the same brand… 😔

[@joebryant5793]

Thanks for the link to the tool, lifesaver!!

[@Dartmech]

You’re welcome! No getting around that thing well worth the $$

[@SrColon309]

mega excellent work and video. Very detailed, precise and clear.

[@Dartmech]

Glad you enjoyed it!

[@gabriela0612gh]

Nice explanation thank you

[@dman0042]

Outstanding

[@DarkSim77]

This job is a lot easier if you have a press and a vise.

[@Dartmech]

MUCH easier.

[@BBDos]

Took my rear differential apart (identical truck), and I had the same clip part run a groove in the diff main bearing cap.the remaining clip fragment stayed in place and kept the clutches intact. Did you reuse the same bearing cap with no issue? Do you recall the pinion nut size?

[@Dartmech]

I reused the cap, no issues 10K+ miles later. I don’t remember the socket size off hand.

[@bobtailsthecat]

Really a fantastic video, I unfortunately have come across broken clutch pack retaining clips. Not looking to do a complete rebuild, just don’t have the time or money right now. Is it possible to replace the broken retaining clips without having to worry about adjustments ? backlash? and anything else ??? Thank you (:

[@Dartmech]

I think you’re out of luck there.. the clips have little bends on other end to keep them from falling out. In order to replace them, the clutch packs will have to come out which mean the diff needs to come out so you’ve gotta do the whole process…. Sorry about that. If you leave the clips totally out so they’re not rubbing on anything like mine were, you’ll probably be fine for a while. However they will eventually start to wear into the diff carrier.

[@bobtailsthecat]

@@Dartmech Thansk for responding. That’s what i was starting to think about since the truck has almost 200k miles, not looking to dump a ton of money or time into it. I just removed the remains of the clips and appears to not have damaged anything. If you remove the carrier, you must rest backlash and preload everything ?

[@takotacarmin3788]

Awesome video! I’ve been working on mine learning along the way and thought, why don’t I make a video to help others figure this out… you beat me to the punch. Great video, you’ve covered just about everything needed. good job brother. What was the torque specs on your ring gear? I’m doing one and everywhere I look says 65 ft-lb.

[@Dartmech]

Hello, thank you for those kind words! Torque on my ring gear was round 100 I think. Per the Motive site: 7/16” bolts get 60-65ftlb, 1/2” get 100-110”.”

[@Keeter94]

Man I’m doing the same job on same rear end. I’m so close I just need to insert spider gears but I didn’t remove the carrier it’s still inside. Is this possible?

[@Dartmech]

I don’t think so unfortunately…. If your clutch packs aren’t too tight they you might be able to smash them in with a brass punch but forget about the curved shims behind them. They’re pretty thin… sorry, good luck whichever route you take!

[@phillipmatthews1557]

Need to know torch pounds for ting gear bolts

[@Dartmech]

Sorry for the late response it’s like 65ftlbs for the rear and 100 for the fronts. Best to consult the manufacturer for specs though.

[@mikegimenez2629]

When taking the play out of the drivers side adjuster. Turn the driver side adjuster all the way in, back off exactly 1/4 turn, then tighten the passenger side adjuster snug. This should get you close to correct backlash. Your welcome.

[@alanstrain801]

Confused on actual measurement from pinion face ? What was your number ?

[@Dartmech]

mine was 2.735," but they'll vary from make/model/etc...

[@bartonwest1124]

Where did you get the clutches

[@Dartmech]

They’re Yukons off Amazon. Just make sure they have your part number. I used summitracing.com to figure that part out but amazon was cheaper than summit so I went with them.

[@kenkayiii]

On the Amazon website, in the reviews was a very informative way of removing and replacing the clutches by making a spreader....you don't need to remove the carrier and reset the backlash...etc. saves a ton of labor and time

[@joebradley1520]

You're not worried about the bearing slipping on the shaft after you honed it out?

[@Dartmech]

Those were purely for the pinion depth measurement , I put new bearings in once it was time to install the pinion. Hope that helps!

[@joebradley1520]

I found another rear end but it has disc brakes and mine is drums, same gear ratio, would it be cheaper to buy new parts for mine or replace the whole axle that has disc brakes? What am I looking at as far as cost value? The parts alone to rebuild is around $1,200 The rear end that I want to put in my truck is disc brakes but it's tight and in good shape, I'm just wondering what I'm getting myself into as far as Master cylinders in brake lines

[@Dartmech]

@@joebradley1520 I was only in for the cost of the Ring/ pinion ($350 but wasn't Necessary as it wasn't bad) the bearings ($200) and Oil. If it hadn't been for the ring/pinion I would have been under $400 for sure. Switching out for discs isn't all that difficult, you'd just need the line from the wheel cylinder to go to the caliper as far as I know.

[@joebradley1520]

I believe you need a proportioning valve also​@@Dartmech