Dana M235 Fluid Change
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Fleet Mechanic
Joined: Dec 2016
Posts: 1,810
Likes: 539
From: Florida
Dana M235 Fluid Change
I hadn't seen much on maintenance for the new Dana M235 9.25" front axle. I did fluid changes on both of my F350's axles today so I figured I'd share a couple pics from the new Dana.
Bottom line is that it's just like every other axle fluid change but the reusable gasket is a game changer (despite Ram using them on their AAMs since at least 2003).
Heavy flow of OEM fluid coming from the fill hole. Not under-filled from the factory on mine.
As expected, the front Dana was really clean. The fill plug was not magnetic, and note the sealing surfaces of the reusable gasket... way more substantial than the 11.6" Sterling's gasket.
The guts. There's a pretty significant pool of gear oil in the bottom of the pumpkin. I swabbed it out to get as much of the OE fluid out as possible. Right at 2.5 quarts went back in (Amsoil Severe Gear 80W-90).
By contrast, the 11.6 bolts were way easier to remove, the gasket was chincy, the cover seemed flimsy, and no oil flowed from the fill plug. The plug had a good bit of wear particles collected and the fluid was a good bit dirtier, also as expected.
11.6 fill plug.
Bottom line is that it's just like every other axle fluid change but the reusable gasket is a game changer (despite Ram using them on their AAMs since at least 2003).
Heavy flow of OEM fluid coming from the fill hole. Not under-filled from the factory on mine.
As expected, the front Dana was really clean. The fill plug was not magnetic, and note the sealing surfaces of the reusable gasket... way more substantial than the 11.6" Sterling's gasket.
The guts. There's a pretty significant pool of gear oil in the bottom of the pumpkin. I swabbed it out to get as much of the OE fluid out as possible. Right at 2.5 quarts went back in (Amsoil Severe Gear 80W-90).
By contrast, the 11.6 bolts were way easier to remove, the gasket was chincy, the cover seemed flimsy, and no oil flowed from the fill plug. The plug had a good bit of wear particles collected and the fluid was a good bit dirtier, also as expected.
11.6 fill plug.
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Fleet Mechanic
Joined: Dec 2016
Posts: 1,810
Likes: 539
From: Florida
17.5k
I mostly just wanted to ensure fluid levels were good and break-in contaminants were out. Will probably change again at 50k, and then every 50k from then on.
I mostly just wanted to ensure fluid levels were good and break-in contaminants were out. Will probably change again at 50k, and then every 50k from then on.
Lead Driver
Joined: Feb 2005
Posts: 7,928
Likes: 2,644
From: The Great State of Texas
OP,
Thanks for sharing...
My '12 with 285k miles still has the factory lube in the front axle. The axle is bone dry externally, but should probably at least check the fluid level and top off if required.
Thanks for sharing...
My '12 with 285k miles still has the factory lube in the front axle. The axle is bone dry externally, but should probably at least check the fluid level and top off if required.
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Fleet Mechanic
Joined: Dec 2016
Posts: 1,810
Likes: 539
From: Florida
My OCD is currently pegging...
Lead Driver
Joined: Feb 2005
Posts: 7,928
Likes: 2,644
From: The Great State of Texas
I know sounds terrible doesn't it ... but in my case the only time I use 4 wheel drive is when driving on wet dirt roads on my hunting property or pulling out of a slippery boat ramp. All other times the rotating assembly is not moving (2wd mode). So I estimate I use my 4 wheel drive ~10% of the time which is ~28k total miles. I think the factory lube is still pristine 
We have a 2002 7.3PSD Super Duty that used for farm work and I can guarantee it still has the factory lube in the front diff. Probably still has factory lube in the rear diff too. A 2005 Dodge 5.9 cummins with ~500k miles and most likely original lube in both diffs, although it's on its 2nd transmission
... but in my case the only time I use 4 wheel drive is when driving on wet dirt roads on my hunting property or pulling out of a slippery boat ramp. All other times the rotating assembly is not moving (2wd mode). So I estimate I use my 4 wheel drive ~10% of the time which is ~28k total miles. I think the factory lube is still pristine We have a 2002 7.3PSD Super Duty that used for farm work and I can guarantee it still has the factory lube in the front diff. Probably still has factory lube in the rear diff too. A 2005 Dodge 5.9 cummins with ~500k miles and most likely original lube in both diffs, although it's on its 2nd transmission
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Cargo Master
Joined: Jul 2011
Posts: 2,664
Likes: 971
From: Walpole, MA
I know sounds terrible doesn't it ... but in my case the only time I use 4 wheel drive is when driving on wet dirt roads on my hunting property or pulling out of a slippery boat ramp. All other times the rotating assembly is not moving (2wd mode). So I estimate I use my 4 wheel drive ~10% of the time which is ~28k total miles. I think the factory lube is still pristine
... but in my case the only time I use 4 wheel drive is when driving on wet dirt roads on my hunting property or pulling out of a slippery boat ramp. All other times the rotating assembly is not moving (2wd mode). So I estimate I use my 4 wheel drive ~10% of the time which is ~28k total miles. I think the factory lube is still pristine 
The fluid that came out of my M256 was nasty, truck had definitely spent some time in and around stagnate water. Oddly enough the gear oil in the rear end didn't seem as bad.
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Mountain Pass
Joined: Aug 2024
Posts: 207
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From: Central New York
Trading the Ram in on a new F-250 Monday.
NYH1.
Cargo Master
Joined: Jan 2017
Posts: 2,247
Likes: 555
Thread Starter
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Fleet Mechanic
Joined: Dec 2016
Posts: 1,810
Likes: 539
From: Florida
Yup. My 2004 2500 Cummins (2nd year of the 3rd gen) had reusable gaskets on both diffs and the tranny. They were stout too.
Mountain Pass
Joined: Aug 2024
Posts: 207
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From: Central New York
NYH1.
Cargo Master
Joined: Jan 2017
Posts: 2,247
Likes: 555
then you must have a golden unicorn. never have i seen one of them trucks with rtv. nor have i ever heard of one with rtv. except yours i guess
More Turbo
Joined: Oct 2020
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BUT I've never pulled the cover for a fluid change, so perhaps it was neatly done in conjunction with the gasket.
Cargo Master
Joined: Jul 2011
Posts: 2,664
Likes: 971
From: Walpole, MA
Next time I do the diffs on my 2019 I will probably throw some lube locker gaskets on it.