Yukon Gear Eight Piece Side Gear and Thrust Washer Kit For Chrysler 8in and 9.25in

A clunk from the rear of a Ram 1500, Dakota or Durango when you shift into Drive, or a knock when you get on and off the throttle, often comes from inside the carrier. When the thrust washers behind the side gears wear thin, the side gears and spider gears pick up slack, and every load change takes it up with a bang. Yukon YSPTW-008 is the side gear thrust washer kit for the Chrysler 8.0 in. and Chrysler-design 9.25 in. differentials, the parts that put that clearance back where it belongs.

What side gear thrust washers do in a Chrysler 9.25 or 8.0

Inside the differential case, the two side gears ride on the axle shaft splines and mesh with the spider (pinion) gears on the cross shaft. When the truck turns, the spider gears walk around the side gears, and the side gears press outward against the case. The thrust washers sit between the back of each side gear and the case so the gears run on a hardened bearing surface instead of the case itself, and their thickness sets how much play the gear set has. As they wear, side gear clearance grows. That slack is what you hear as a clunk on engagement and on throttle changes, and it lets the gears load on the tips of the teeth, which speeds up wear. Note that Yukon describes YSPTW-008 as a six-piece kit, even though some catalog titles, including ours, call it an eight-piece kit; it contains the washers, not new side gears.

Symptoms of worn side gear thrust washers

• Clunk from the axle when shifting from Park to Drive or Reverse
• Knock or bang on and off the throttle, and when taking off from a stop
• Clicking or ratcheting in tight, slow turns, such as parking lot maneuvers
• Bronze-colored or fine metallic paste on the drain plug or cover magnet
• Visible play when you rock a side gear by hand with the cover off

How to confirm before you buy

Driveline clunk has other causes, so rule them out first: worn U-joints, a loose yoke nut, worn leaf spring bushings and a worn slip yoke all make similar noises. With the cover off and the truck safely supported, rock a tire back and forth with the other wheel held and watch the gears. If the side gears and spiders move noticeably before the ring gear does, the washers are worn. Our spider gear failure guide explains how to tell washer wear from broken teeth. If the gear teeth are chipped or the cross shaft is grooved, replace the gears as well, not just the washers.

Fitment

YSPTW-008 is listed for the Chrysler 8.0 in. and 9.25 in. differentials. The 8.0 in. is the independent front differential in 4WD Dakota, early-2000s Durango and Ram 1500 trucks (the same axle our Yukon 8.0 IFS ring and pinion fits), and the 9.25 in. is the Chrysler-design semi-float rear with the 12-bolt cover under Ram 1500, Dakota, Durango, Aspen and Raider. It does not fit the ZF-built 9.25 rear in later Ram 1500s, which uses Yukon's separate YSPTW-076 kit, and it is not for the AAM 9.25 front used on Ram heavy-duty trucks. Our Chrysler 9.25 axle guide shows how to identify which axle you have by the cover and tag. If you are not sure, send us your year and VIN before you order, and measure your old washers so you can compare them with the new ones.

Install notes

• Drain the gear oil, pull the cover, and remove the cross shaft lock bolt and cross shaft. On the C-clip rear, push the axles in and remove the clips before sliding the shafts out.
• Roll the spider gears out of the case, remove the side gears, and clean the case thrust surfaces. Look for scoring in the case; a damaged case will wear new washers fast.
• Lubricate the new washers with gear oil, install the side gears and spiders, and check side gear play against the service manual before reinstalling the cross shaft.
• Use a new cross shaft lock bolt or thread locker, and refill with the gear oil grade your owner's manual calls for. Trac-Lok carriers need friction modifier; see our friction modifier guide.

If the Trac-Lok clutches are chattering while you are in there, add the Yukon Chrysler 9.25 Trac-Lok clutch kit. For a whining 9.25 rear with bearing wear, the Chrysler 9.25 rear master overhaul kit covers the carrier and pinion bearings and seal. If you are resetting pinion preload at the same time, the Yukon crush sleeve eliminator kit replaces the factory crush sleeve with a solid spacer and shims.

Does YSPTW-008 include new side gears?

No. Despite the side gear wording in the title, it is a thrust washer kit. Yukon describes it as six pieces, the washers that sit behind the side gears and spider gears. If your gears are chipped or worn, buy a spider gear set as well.

Will this fit the 9.25 in my 2015 Ram 1500?

Probably not. Later Ram 1500s use a ZF-built 9.25 rear, which takes Yukon's YSPTW-076 kit. YSPTW-008 is for the Chrysler-design 9.25 rear and the Chrysler 8.0 front. Check the cover bolt count and axle tag, or send us your VIN.

Can worn thrust washers cause a clunk when shifting into gear?

Yes. Worn washers let the side gears and spider gears move before they load up, and that free play is taken up with a clunk on engagement and on throttle changes. Rule out U-joints, the yoke nut and spring bushings first.

Do I need to remove the carrier to replace the washers?

On most units no. With the cover off you can remove the cross shaft, push the axles in to free the C-clips on the rear, and roll the gears out of the case. Pull the carrier only if the bearings or ring gear also need service.

What gear oil should I use after the job?

Use the grade your owner's manual lists for the axle. If the axle has a Trac-Lok limited slip, add friction modifier unless the oil already contains it.