3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

Broken diff cover bolt - AAM 9.25 front diff

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Old Jun 5, 2014 | 10:46 PM
  #1  
afate45's Avatar
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Broken diff cover bolt - AAM 9.25 front diff

Apparently I don't know my own strength, or the bolt was on it's way out. Broke the bolt in two before reaching 30 ft lbs.

Anyone know what size the differential cover bolts are on a 9.25 AAM front differential? I'm guessing I could get a suitable bolt at a local auto parts store, but just curious if anyone knows the size?

This is on an 03 Ram 2500 4x4.

thanks!
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Old Jun 6, 2014 | 07:27 PM
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Jeff in TD's Avatar
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From: Oregon
Don't know the size off the top of my head, but I had one snap before reaching specified torque on my 03 too.

They seem to be pretty hard and/or brittle. Fortunately mine removed easily with a left twist drill bit. I just took the broken one to the store.

Now I torque them to like 26, and have had neither leak or another broken bolt.
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Old Jun 7, 2014 | 12:01 AM
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Update: I figured this out. M8 - 1.25 - 25mm. 20mm will also work, but I went with 25mm. 10.9 is the bolt class.

You can find these at your local auto parts store...I picked mine up from Advanced Auto Parts. Take note though, the bolt head will be slightly smaller. I couldn't find any that had the 1/2in bolt head, these are 12mm (with the flange)...they work just fine.

Hope that helps someone down the road.
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Old Jun 7, 2014 | 12:08 AM
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Oops, only TQ them to 25 ft/lbs or they will break. Little late now.
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