1993 DODGE TRUCK Service Repair Manual

2
- 36
FRONT
SUSPENSION
AND
AXLE

• • Pinion gear mate shaft (align holes in shaft and
case) (2) Install and seat the lock pin in the differential
case and mate shaft with a punch and hammer (Fig.
50).
Peen metal part of case over pin in two places.
If replacement gears and thrust washers were
installed, it is not necessary to measure the gear
backlash. Correct fit is due to close machining
tolerances during manufacture.

Fig.
50
Mate
Shaft Pin
installation

(3) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment (Fig. 51).
(4) Install new ring gear bolts and alternately
tighten to 61-81 N*m (45-60 ft. lbs.) torque.
(5) Lubricate all differential components with hy­
poid gear lubricant.
(6) Place Master Differential Bearing D-345
(D-135) on the case hubs (Fig. 52).
(7) Install a pilot stud at the right side of housing.
Attach Dial Indicator C-3339 to the pilot stud. Load
indicator plunger against the back of the ring gear (Fig. 53).
(8) Insert a small pry bar between the bearing cap
and left side of differential case. Pry the case as far as possible to right side (Fig. 53). Zero the dial indi­
cator pointer.
(9) Pry the case to left side and record the travel
distance. The measurement above is the shim thickness
necessary for case zero end-play. The total
thickness will be determined during the ring gear backlash adjustment. (10) Remove indicator and pilot stud.
TORQUE

Fig.
51
Ring
Gear
Bolt
Hole
Installation
SPECIAL
TOOL

D-345

J9203-20

Fig.
52 Master Bearing Tools On
Hubs

PINION GEAR DEPTH INFORMATION Gears are supplied as matched sets only. The iden­
tifying numbers for the ring and pinion gear are etched into the face of each gear (Fig. 54). A plus
(
+ )
number, minus (-) number or zero (0) is etched into
the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best tooth contact pattern.

•

Fig,
53
Differential
Case
End Play Measurement
DRIVE
PINION

Fig.
54
Pinion
Gear ID
Numbers
The standard depth is the distance (Fig. 55) from
the centerline of the axle shaft/ring gear to the shoulder of the rear pinion bearing.
Compensation for depth variance is achieved by
shims placed adjacent to the pinion gear rear bearing
cup (Fig. 56).
If a new gear set is being installed, note the depth
variance etched into the original and new pinion
gear. Add or subtract the thickness of the original
depth shims to compensate for the difference in the
depth variances. Refer to the Depth Variance charts.
For Example:
• If a positive marking, this means the shim pack
must decrease by the same number of thousandths. • If a negative marking, this means the shim pack
must increase by the same number of thousandths.
FRONT
SUSPENSION
AND
AXLE
2 - 37

Fig.
55
Pinion
Gear Standard Depth/Distance
DRIVE

Fig.
56
Shim
Locations
• If marked zero will use the nominal setting as de­
termined in this procedure.
Shims are available in 0.003-inch, 0.005-inch,
0.010-inch, and 0.030-inch thicknesses.
If original gear set is installed but the depth shims
replaced, measure the thickness of the original depth shims. Build a replacement pack of depth shims with
the same thickness.
If equipped, the oil slinger must be measured
and the thickness included with the total shim
pack thickness.
The shim thickness for the new pinion gear must
be determined before installing the differential case.
AXLE
DEPTH

MODEL
SETTING

2
- 38
FRONT
SUSPENSION
AND
AXLE

•
PINION GEAR DEPTH VARIANCE

Or§@ift^i
Linton
IsptocMnwtt
HnS®n
Oior Itoplli
fflttanct

Or§@ift^i
Linton
-4
-2

-1
0

+
1

-ft
+3
+4
+4
+
0.008
+
0.007

+
0.006
+
0.005
+
0.004

+
0.003
+
0.002
+
0.001
0

+3
+
0.007
+
0.006
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001
0
-0.001
+2
+
0.006
+
0.005
+
0.004

+
0.003
+
0.002
+
0.001
0
-0.001

-0.002

+
1
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001
0
-0.001
-0.002

-0.003

0
+
0.004

+
0.003
+
0.002

+
0.001
0

-0.001
-0.002
-0.003

-0.004

-1
+
0.003

+
0.002
+
0.001
0
-0.001
-0.002

-0.003 -0.004
-0.005

-2
+
0.002
+
0.001
. 0
-0.001

-0.002
-0.003 -0.004
-0.005 -0.006

-3
+
0.001
0
-0.001
-0.002

-0.003 -0.004
-0.005 -0.006

-0.007

-.4
0
-0.001
-0.002

-0.003 -0.004 -0.005
-0.006
-0.007

-0.008
PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH TOOL SET D-11144
The following gear depth measurement and adjust­
ment procedure involves using Tool Set D-115-44. (1) Insert Master Pinion Block D-139 into the
dif­

ferential housing (Fig. 57).

PINION BLOCK TOOL PINION BLOCK TOOL
J8902-46

DIFFERENTIAL
HOUSING

ARBOR
DISC
TOOL
ARBOR

TOOL
J9003-103
DIFFERENTIAL

HOUSING
J9003-101
Fig.
57
Pinion
Block
In Shaft
Bore

(2) Place Disc D-115-4 on Arbor D-115-3 and posi­
tion in the bearing cradles (Fig. 58). This is the cen­
terline of the ring gear/axle shaft. (3) Place Pinion Height Block D-115-1 on top of
master pinion block tool and against arbor tool (Fig.
59).

(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step of block tool (Fig. 60). Zero
the dial indicator pointer.
Fig.
58
Disc
&
Arbor
In
Housing

(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
60).
Slide the gauge block across the arbor while ob­
serving indicator. Record the longest travel distance,
whether inward (-) or outward (+•), indicated by the
pointer.
The distance indicated, plus or minus the
amount etched in the gear is the required thick­

ness.

(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim pack thickness if
required.
(7) Remove the measurement tools from the differ­
ential housing.

•

FRONT
SUSPENSION
AND
AXLE
2 - 39

Fig.
59
Pinion
Height
Block
Against
Arbor
Fig.
60
Pinion
Gear Depth Measurement
(8) Place the depth shims in the pinion gear rear
bearing bore. Install the bearing cup (Fig. 61) with Installer D-145 and Handle C-4171.
Ensure the cup is correctly seated. (9) Install the pinion front bearing cup with In­
staller D-144 and Handle C-4171 (Fig. 62).
(10) Install the rear bearing (and slinger if used)
on the pinion gear with Installer W-262 until com­
pletely seated (Fig. 63).
(11) Assemble preload shims onto pinion and in­
stall the pinion gear in housing.
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer C-3718 and Wrench C-3281 (Fig. 64).
(13) Tighten the yoke nut to 271-298 N-m (200-220
ft. lbs.) torque. (14) Check bearing preload torque with an inch
pound torque wrench (Fig. 65). The torque necessary
to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.)
• New Bearings — 2 to 5 N*m (20 to 40 in. lbs.)
SPECIAL
TOOL

C-4171
J9202-95
Fig.
61
Pinion
Rear Bearing Cup
Installation
SPECIAL
TOOL
D-144
SPECIAL Fig.
62
Pinion
Front Bearing Cup
Installation

If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.
66);

• Increase the preload torque, decrease the shim
thickness
• Decrease the preload torque, increase the shim
thickness
(15) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 67).
(16) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 68) with
Installer W-147-E and Handle C-4171
(17) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 64). (18) Install a new yoke nut and tighten to 271 to
298 N-m (200 to 220 ft. lbs.) torque.

2
- 40
FRONT
SUSPENSION
AND
AXLE

•

SHIM PACKS
RY660
J9103-21

Fig.
64
Pinion
Yoke
Installation

PINION
GEAR
DEPTH
MEASUREMENT AND

ADJUSTMENT
WITH
TOOL
SET
C-3715-B The alternate measurement and adjustment proce­
dure involves using Axle Measurement Gauge Set C-3715-B. (1) Install the pinion rear bearing cup (Fig. 69)
with Installer D-145 and Handle C-4171 (2) Install the pinion front bearing cup with In­
staller D-144 and Handle C-4171 (Fig. 70). Ensure the cup is correctly seated.
Assemble
C-3715-B
Tool Set as described;
Fig.
66
Shim
Locations

• Position Spacer (SP-5586) over Shaft (SP-5385)
• Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-5585)
• Install pinion front bearing
m Install Sleeve (SP-3194-B), Washer (SP-534) and Nut (SP-3193) (3) Prevent compression sleeve tool from turning
with Wrench C-3281. Tighten the nut to seat the pin­
ion bearings in the housing (Fig. 71). Allow the
sleeve to turn several times during the tightening to
prevent brinelling the bearing cups or the bearings.
Depth shim(s) are positioned between the pin­
ion gear rear bearing and pinion gear to provide

•

FRONT
SUSPENSION
AND
AXLE
2 - 41

SPECIAL
TOOL
D-145
Fig.
67
Pinion
Yoke
Removal
HANDLE
C-4171
SPECIAL

TOOL

C-4171
J9202-95 Fig.
69
Pinion
Rear Bearing Cup
Installation

SPECIAL
TOOL
D-144
SPECIAL

TOOL

C-4171

SPECIAL
TOOL

W-147-E
(J25104)

J9202-19
Fig.
68
Pinion
Seal
Installation
the separation distance. The required thickness
of the depth shim(s) is determined according to
the following information.
(4) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri­ cant. Re-tighten the compression nut tool to 1 to 3
N«m (15 to 25 in. lbs.) torque. Rotate the pinion gear
several complete revolutions to align the bearing
rollers.
(5) Install Gauge Block SP-5260 at the end of SP-

526.
Install Cap Screw (SP-536) and tighten with
Wrench
SP-531.

(6) Position Crossbore Arbor (SP-5183) in the
dif­

ferential housing.
J9202-35
Fig.
70
Pinion
Front Bearing Cup
Installation
Center the arbor in cradles so equal space exists at
both ends. Position the bearing caps on the arbor
tool. Install the bolts. Tighten the cap bolts to 14 N*m (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) or feeler gauge between
the crossbore arbor and gauge block (Fig. 72). The fit must be snug but not tight (drag friction of a
feeler gauge blade).
Depth shims are available in 0.001-inch incre­
ments from 0.020 inch to 0.038 inch.
(8) Note the etched number on the face of the drive
pinion gear (e.g., -0, -1, -2, +1, +2, etc.). The num­
bers represent thousands-of-an-inch deviation from
the standard. If the number is - (negative), add that value to the required thickness of the depth shim(s).
If the number is + (positive), subtract that value

2
- 42
FRONT
SUSPENSION
AND
AXLE

DIFFERENTIAL HOUSING HAMMER
DRIVER
HANDLE
YOKE
HOLDING TOOL
C-3281

Fig.
71 Seating Pinion Bearings SPACER
J9002-91

DEPTH
SHIMS
HERE
REAR
PINION

BEARING

SHAFT

BEARING
CAP ARBOR
J9203-53

Fig.
72 Depth Shim(s) Selection from the thickness of the depth shim(s). If the num­
ber is 0, no change is necessary.
(9) Remove the tools from the differential housing.
(10) Remove the rear bearing cup from housing
(Fig. 73). Use Remover D-162 and Handle C-4171. (11) Position depth shims in housing rear bearing
cup bore.
(12) Install the pinion rear bearing cup (Fig. 70)
with Installer D-145 and Handle C-4171.
Ensure the cup is correctly seated. (13) If the depth of mesh has been followed accord­
ing to the instructions above, good gear teeth contact
should exist.
(14) Install the rear bearing (and slinger if used)
on the pinion gear with Installer W-262 until com­
pletely seated (Fig. 74).
(15) Install pinion in housing bore.
(16) Assemble preload shims onto pinion and in­
stall the pinion gear in housing. (17) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer C-3718 and Wrench C-3281 (Fig. 75).
J9203-58

Fig.
73 Rear Bearing Cup
Removal
PRESS
•

DRIVE

PINION
GEAR

SHAFT

REAR BEARING
^
INSTALLATION
TOOL
DRIVE

PINION
GEAR
OIL

SUNGER

J9302-68

Fig.
74
Pinion
Rear Bearing
Installation
(18) Tighten the yoke nut to 271-298 N-m (200-220
ft. lbs.) torque.
(19) Check bearing preload torque with an inch
pound torque wrench (Fig. 76). The torque necessary to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N-m (10 to 20 in. lbs.)
• New Bearings — 2 to 5 N-m (20 to 40 in. lbs.) If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.
77);

FRONT SUSPENSION
AND
AXLE
2 43

SPECIAL
DIFFERENTIAL
TOOL
HOUSING J9103-21

Fig. 75 Pinion Yoke Installation
Fig. 76 Rotating Pinion Gear • Increase the preload torque, decrease the shim
thickness • Decrease the preload torque, increase the shim
thickness
(20) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 78).
(21) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 79) with
Installer
W-147-E
and Handle C-4171.
(22) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 80).
(23) Install a new yoke nut and tighten to 271-298
N*m (200-220 ft. lbs.) torque.
REMOVE
SHIMS

SHIM
PACKS
RY660
Fig. 77 Shim Locations

C-452
J9102-31
Fig. 78 Pinion Yoke Removal
RING
GEAR BACKLASH
ADJUSTMENT

(1) Place Master Differential Bearing D-135
(D-345) on the case hubs.
(2) Install a pilot stud at the right side of housing.
Attach Dial Indicator C-3339 to the pilot stud. Load indicator plunger against the back of the ring gear (Fig. 81). Ensure ring and pinion gear teeth are
tightly meshed. Zero the indicator.
(3) Insert a small pry bar between the bearing cap
and left side of differential case. Pry the case as far
as possible to right side (Fig. 81). Zero the dial indi­
cator pointer.
(4) Repeat the measurement several times to check
consistency. Record the travel distance.