Weak links. Every truck has them: the part in the system that’s just a bit weaker than the rest. Some become apparent when you add copious amounts of power. Others make themselves known with age. The front axle in the ’99 to ’08 Dodge 2500/3500 and ’99 to ’04 Ford Super Duty trucks are great examples. Overall, these are pretty good assemblies, but they use unit bearings, which become a weak link over time. It’s natural for bearings to wear, but when these fail, the front wheel can part ways with the truck. And if you’ve added more power and larger tires, you’ve shortened the life expectancy of the stock unit bearings considerably. The other big weak link in these front-axle assemblies is the steering joints. The stockers are generally OK if you haven’t added power or larger tires, but do both and you’ll find the limit pretty soon.
We decided to be proactive and upgrade both the steering joints and the unit bearings in this ’03 Dodge Ram 2500. The truck has moderate power upgrades and stock tires. The unit bearings were starting to make noise, which means the pin had been pulled on the grenade and it was just a matter of time. We took the truck to Unlimited Offroad Centers in Fenton, Michigan, to install a Spyntec hub conversion kit that replaces the non-serviceable unit bearing with a traditional spindle, hub, and bearing assembly. We also upgraded the axleshafts with an RCV Ultimate CV axle set. The shafts are made from aircraft-quality steel and the CV joints are engineered to handle serious abuse while eliminating the crow hop you experience while turning corners in four-wheel drive. The new axleshafts and CV joints are so strong that RCV offers a “You break it, we replace it” warranty. We’ll give it our best shot.
01. Both upgrades require...
01. Both upgrades require much of the same installation work, so we did both at the same time. Eric Matney and Justin Whalen at Unlimited Offroad Centers tag-teamed the job. The hardest part is getting the original unit bearing off the truck. First, the brake caliper and rotors need to be removed. The calipers can be hung off the frame with a strap during the rest of the installation.
02. With a Spyntec hub conversion...
02. With a Spyntec hub conversion and RCV axleshaft upgrade, the 9.25-inch front axle in ’02 to ’08 Dodge heavy-duty trucks becomes pretty much bulletproof. In addition to stronger components, the hub conversion will give you a slight improvement in fuel economy when you unlock the hubs and stop all the internal parts from spinning when the truck is in two-wheel drive.
03. Use an Allen wrench to...
03. Use an Allen wrench to unbolt the ABS sensor from the top of the unit bearing assembly. It’s pretty common for these to break when you remove them. If the plastic cover is missing from the sensor when you pull it out like this one, you’ll need to get a new sensor.
04. On the back of the spindle,...
04. On the back of the spindle, there are four bolts that attach the unit bearing. You’ll have to move the steering from left to right to remove all four bolts.
05. This next step can be...
05. This next step can be really challenging. The unit bearing is a tight fit on the spindle and any amount of corrosion seizes it in place. Shown in the photo is a unit-bearing puller, which is a good investment if you’re going to work on several trucks. In the next photo, we’ll show you how to do it with handtools you already own.
06. Straighten the steering...
06. Straighten the steering wheel and find a socket extension that fits with the correct socket for the unit-bearing bolt. Insert the top rear bolt until it is about 1/2-inch from being tight against the spindle. Place the socket and extension combo on the bolt and secure it against the suspension bracket on the axlehousing. Have someone start the truck and slowly turn the wheel to use the truck to press the unit bearing out of the spindle.
07. With the unit bearing...
07. With the unit bearing removed, the axleshaft assembly simply slides out of the housing. Some axle oil will most likely come out with the axleshaft, so be ready with shop towels to catch the dribble. Stuff a towel in the end of the housing to keep debris from entering it and use a wire brush to clean the inside circumference of the spindle.
08. CV shafts have a bad...
08. CV shafts have a bad rap in the off-road industry, but RCV is out to change that. The CV joints are made from billet steel for strength, and the shafts are made from aircraft-quality steel. The joints can provide up to 45 degrees of smooth steering angle, and (most importantly) they can handle the power your Cummins engine produces. The RCV Ultimate CV axle set is available as a direct replacement if you’re retaining the unit bearings, or with the proper stubshaft to work with the Spyntec hub conversion.
09. The RCV shafts include...
09. The RCV shafts include a patented spherical boot to seal the CV bell. An installation tool is also included. The orange boot is also a bragging point that you’ve upgraded to these ultimate axles. Slip the boot over the end of the shaft and slide the shaft into the housing. Position the installation tool between the boot and the end of the housing and then push the axleshaft the rest of the way into the housing. The seal will pop into place.