- Posted by Matt Gieselman on October 21, 2009
Parts Required:
- Axle retaining nuts and bolts x 8 Chrysler part 5080665AA (Do not reuse the old bolts and nuts, the nuts I got from a hardware store, they are 3/8” x 24 thread lock nuts.)
- Bearing, bearing retainer and axle seal x 2 (Randy’s Ring and Pinion, about $100 with shipping.)
- RTV
- Brake or other high temperature grease
Tools Required:
- Torque wrench
- Metric box wrench set
- Dead blow hammer (Only if your rotors are stuck)
- Spring hook tool
- C clamp
Torque Values:
- Caliper bolts – 11 ft/lb
- Lug nuts – 85 – 115 ft/lb
 | After removing the wheels compress the caliper using a C clamp, this will make removing and installing the caliper easier. |
 | Remove the caliper bolts then remove the caliper by pulling at the bottom perpendicular to the axle. Use a zip tie to secure the caliper so it doesn’t hang by the brake hose. |
 | With the caliper out of the way remove the rotor, if it’s stuck you can use a dead blow hammer or rubber mallet to provide some persuasion. |
 | Remove the spring using the spring hook tool. Next remove the adjuster and the two hold down clips. |
 | Remove the return spring, then the parking brake shoes by pulling them away perpendicular to the axle. |
 | Remove the retaining plate nuts, as you can see mine were coated in differential lube where the axle seal failed.
Pull firmly on the end of the axle shaft and it should pull out, the bearing race may stay in the end of the axle housing, you should be able to pull it out by hand. |
 | Clean up the brake parts with degreaser and brake cleaner, be sure not to get any breaker cleaner on any of the painted or rubber parts. |
 | I took my shafts to a machine shop and had them remove the bearing retainer and bearing and install the new parts.
If you have a drill press the bearing retainer can be removed by drilling a 3/8” hole in the retainer then using a chisel to crack and remove the retainer.
The bearing can be removed using a splitter and shop press. |
 | Put a thin coat of axle grease on the inner surface of the seal before installing it on the axle shaft.
Before installing the axle shaft put a thin coating of RTV on the axle seal to help ensure a leak free seal. |
| | During assembly be sure to lube the caliper bolts and anti-rattle clips with brake or high temperature grease. |
- Posted by Matt Gieselman on October 15, 2009
My passenger side door lock died a slow death and finally stopped working, after picking up the service manual on eBay I decided to give repairing the lock myself a go. This procedure is for the passenger side door, the driver side will be similar but not identical because of the lock cylinder.
Parts Required:
- Passenger side door lock actuator 72115-SDA-A01
- Driver side door lock actuator 72155-SDA-A01
Tools Required:
- Trim pad remover (I picked one up at Sears for $8)
- Phillips screwdriver
- Flat head screwdriver
- 10mm socket
- 8mm socket
 | Lower window glass fully then remove the mirror mount cover by pulling at the top and lifting up. |
 | Pull back the inner handle and push in on the notch at the bottom, this will pop out the cover. |
 | Remove the 2 bolts holding the inner handle then remove the handle. |
 | On the backside of the inner handle is the inner handle cable, rotate the blue cable latch 90 degrees and then remove the cable latch head and pull out on the green retainer. |
 | Remove the pull pocket lid then remove the phillips screw. |
 | Remove the 3 screws behind the inner door handle. |
 | Now remove the 8 trim pad clips with the trim pad remover tool. Once all 8 pads are removed start with the back of door panel and pull upward, be sure not to use too much force.
The door panel should come off without too much effort, once it does unplug the door switch harness and courtesy light plug. |
| | Raise window glass fully and pull away the white plastic sheet starting with the end by the lock, only pull it back halfway. |
 | With the plastic sheet our of the way remove the glass channel retainer bolt, then remove the retainer by pulling down until it is completely off the rubber channel. |
 | Disconnect the outer handle rod, first rotate the plastic retainer clip 90 degrees then pull the rod out. |
 | Remove the screw securing the lock knob and the 2 clips holding the inner handle cable. |
 | Detach the actuator connectors and cable clip. |
 | Remove the 3 screws holding the latch and remove the latch through the hole in the door. |
 | The latch mechanism. |
 | Remove the plastic access cover to allow access to the lock actuator. |
 | Once the access cover is removed you can see the lock actuator and the screw that holds it in place. |
 | Rotate the purple retainer clip and remove the door lock cable, next remove the actuator retainer screw. |
 | Now that disassembly is complete install the new actuator and reassemble the door. |