1993 DODGE TRUCK Service Repair Manual

2
- 44
FRONT
SUSPENSION
AND
AXLE

Fig.
79
Pinion
Seal
Installation
SPECIAL
DIFFERENTIAL
TOOL
HOUSING

J9103-21

Fig.
80
Pinion
Yoke Installation The measurement shows shim thickness neces­
sary to eliminate ring gear backlash. Subtract
this thickness from case zero end-play shim
thickness. The shims must be placed at the ring gear side between the case and bearing.
(5) Remove indicator and pilot stud.
(6) Remove the differential case from housing.
(7) Remove the master bearing tools from the
dif­

ferential case hubs. •

Fig.
81
Ring
Gear
Backlash
Measurement (8) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear­ ing on the hub with Installer D-156 and Handle
C-4171 (Fig. 82).

Fig.
82
Differential
Bearing Installation
(9) Position the remaining zero end-play shims on
hub at opposite side of case. Include an additional 0.015-in (0.38-mm) thick shim on this hub. This will
provide the required differential bearing preload torque.

4
____________
(10) Install bearing
on hub
with Installer
D-156

and Handle C-4171
(Fig. 82).
(11) Install
new
axle shaft
oil
seal
in
differential
housing with Installer D-112-44. Apply lubricant
to
lip
of
seal. (12) Match each bearing
cup
with bearing (origi­

nal).
Install
the
cups
on the
bearings.
(13) Position Spreader W-129-A with
the
tool
dowel pins seated
in the
locating holes
(Fig. 83). In­

stall
the
holddown clamps
and
tighten
the
tool turn-
buckle finger-tight.

Fig.
83
Differential
Housing
Separation
(14) Install
a
pilot stud
at the
left side
of the dif­

ferential housing. Attach Dial Indicator
to
housing
pilot stud. Load
the
indicator plunger against
the op­
posite side
of the
housing
(Fig. 83) and
zero
the
indi­ cator.

CAUTION:
Do not
spread
over
the
specified
dis­

tance.
If the
housing
is
over-separated,
it
could
be
distorted
or
damaged.

(15) Separate
the
housing enough
to
install
the

case
in the
housing. Separate housing
a
maximum distance
of 0.38 mm
(0.015
in)
with
the
spreader
tool. Measure
the
distance with
the
dial indicator (Fig.
83).

(16) Remove
the
dial indicator.
(17) Install case
in the
housing. Ensure
the
differ­
ential bearings
are
fully seated. Remove
the
spreader.
(18) Observe
the
assembly reference marks
and po­

sition
the
bearing caps
at
their original locations (Fig.
84).
Tighten
the
bearing
cap
bolts
to
95-122
N-m (70-90
ft. lbs.)
torque.
(19) Rotate assembly several revolutions
to
seat
bearings. Measure backlash
at
three equally spaced locations with
a
dial indicator
(Fig. 85).
FRONT
SUSPENSION
AND
AXLE
2 - 45

Fig.
84
Differential
Bearing
Cap
Reference Letters
Fig.
85
Ring Gear
Backlash
Measurement
The ring gear backlash must
be
within 0.004
-

0.009 inch
(0.10 - 0.23 mm). It
cannot vary more
than 0.002 inch
(0.05 mm)
between
the
points checked.
(20) Excessive backlash
is
corrected
by
moving
the

ring gear teeth closer
to the
pinion gear teeth.
Insuf­

ficient backlash
is
corrected
by
moving
the
ring gear away from
the
pinion gear. Backlash correction
is ac­

complished
by
transferring shims from
one
side
to

the other.
If
the
mesh
and
backlash steps have been followed
in
the
procedures above, good gear teeth contact pat­
terns should exist.
RING
mMR
TEETH
CONTACT
PATTERN
ANALYSIS The ring gear teeth contact patterns will show
if

the pinion gear depth shim(s) have
the
correct thick­
ness.
It
will also show
if the
ring gear backlash
has

been adjusted correctly.
The
backlash must
be
main­ tained within
the
specified limits until
the
correct
teeth contact patterns
are
obtained.

2
- 46
FRONT
SUSPENSION
AND
AXLE

• (1) Apply a thin coat of hydrated ferric oxide, to
the ring gear teeth. (2) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This action will produce distinct contact pat­
terns on both the drive side and coast side of the ring gear teeth.
(3)
Note patterns in compound. Refer to (Fig. 86)
for interpretation of contact patterns and adjust ac­ cordingly.
(4) Install the axle shafts. Refer to Axle Shaft In­
stallation within this group.

(5)
Install the housing cover. Refill the differential
with lubricant. Refer to Axle Shaft Installation.

FRONT
SUSPENSION
AND AXLE
2 - 47

DRIVE
SIDE
OF RING

GEAR
TEETH
HEEL

TOE
COAST
SIDE
OF RING

GEAR
TEETH TOE

HEEL
DESIRABLE
CONTACT PATTERN.
PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH. PATTERN SHOULD BE CENTERED
ON

THE COAST SIDE OF TOOTH, BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE
SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP
OF

THE TOOTH.
RING GEAR
BACKLASH
CORRECT

THINNER
PINION GEAR DEPTH SHIM REQUIRED.
RING GEAR
BACKLASH
CORRECT.

THICKER
PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT
DECREASE
RING

GEAR
BACKLASH.

PINION GEAR DEPTH SHIM

CORRECT
INCREASE
RING

GEAR
BACKLASH.

Fig.
86 Gear
Teeth
Contact Patterns
J9003-24

2
- 48
FRONT
SUSPENSION
AND
AXLE

•
SPECIFICATIONS

MODEL
44 FRONT
AXLE

Axle
Type
Semi-floating, hypoid
Application
D-TRK
Ring
Gear
Diameter
8.50 in.
(21.59
cm)
Lubricants
MOPAR
Gear Lubricant or
equivalent
SAE
75W-90,

API
Grade
GL-5,
MIL-L-2105C

Disconnect
Type
Vacuum
operated

Lubricant Capacity 5.6 pts.
(2.65L)

Axle Model Dana M44F
Axle Ratio.. 3.54 To
1
3.92 4.09

Track
66.9 in.

GAWR
3500
lbs.
Differential
Bearing
Preload Shim 0.015 in. 0.38 mm

Differential
Side

Gear-to-Case
Clearance..
0.000-0.007
in.
0.00-0.18
mm

Ring
Gear
Backlash
0.005-0.008
in.
0.12-0.20
mm

Drive
Pinion Gearshaft Bearing Break-Away Preload
Torque

Original
Bearings
10-20 in. lbs.
1
-2 N»m Replacement
Bearings
20-40
in. lbs. 2-5 N»m

Drive
Pinion Gear Depth Select
shims
Standard
Setting
2.625
in. 66.6 mm

Side
Gear Clearance (max.)...
0.006
in. 0.15 mm

Case
Runout
(max.)
0.006
in. 0.15 mm
J9202-106

•

FRONT
SUSPENSION
AND
AXLE
2 - 49
MODEL
60 FRONT
AXLE

INDEX

page

Axle Shaft
and
U-Joint
Service
55
Complete Axle Removal/Installation
59

Differential
Assembly
63

Differential
Disassembly
59

Drain
and Refill
51

General
Information
49

Locking
Hubs,
Spindle
and
Axle Shaft
52

Lubricant
51
page

Pinion Gear Depth Measurement
and
Adjustment
with
Tool
Set
C-758-D6
68

Pinion Gear Depth Measurement
and
Adjustment
with
Tool
Set
D-116
66

Pinion Shaft Seal
51

Specifications
75

Steering Knuckle, Upper
and
Lower Kingpins
. . . 56

GENERAL
INFORMATION
Model
60
front axles
(Fig. 1)
consist
of an
iron cen­
ter casting with axle shaft tubes extending from
ei­

ther side.
The
tubes
are
pressed into
and
welded
to

the differential housing. The integral type housing, hypoid gear design
has

the centerline
of the
pinion
set
below
the
centerline of
the
ring gear. The axles
are
equipped with full-floating axle

shafts,
meaning that loads
are
supported
by the
spin­
dles attached
to the
steering knuckles.
Two
tapered
opposed roller bearings allow
the hub and
rotor
as­

sembly
to
rotate
on the
spindle. The removable, stamped steel cover provides
a

means
for
inspection
and
service without removing
the complete axle from
the
vehicle.
A small, stamped metal axle gear ratio identifica­
tion
tag is
attached
to the
housing cover
via one of

the cover bolts. This
tag
also identifies
the
number
of

ring gear
and
pinion gear teeth.
The differential case
is a
one-piece design.
The dif­

ferential pinion mate shaft
is
retained with
a
roll
pin. Differential bearing preload
and
ring gear back­ lash
are
adjusted
by the use of
shims located between
the differential bearing cones
and
case.

BEARING SEAL BUSHING SLINGER

U-JOINT
AXLE
SHAFT

NUT
WASHER
SPINDLE STEERING
ARM AND CAP
STUDS

LEFT

STEERING KNUCKLE
BEARING CAP

f

BOLT

Fig. 1 Model 60 Front Axle
MATE

SHAFT
SCREW
GASKET
OR

SEALER

COVER
PLUG

J9202-67
oi
30
O

e
m

22

o

>•
x
w

FRONT
SUSPENSION
AND
AXLE
2 - 51

LUBRICANT

Multi-purpose API GL 5 quality hypoid gear lubri­
cant should be used for Model 60 axles. MOPAR Hy­
poid Gear Lubricant conforms to these specifications and is recommended.

CAUTION:
If a front axle is
submerged
in
water,
the
axle lubricant
must
be replaced immediately.

DRAIN AND REFILL
(1) Drive the vehicle until the gear lubricant
reaches normal operating temperature. (2) Raise and support the vehicle.
(3) Remove the lubricant fill hole plug from the
differential housing cover. (4) Remove the differential housing cover. Allow
the original lubricant to completely drain from the
housing and axle shaft tubes. (5) With standard differential, clean the differen­
tial and the housing cavity with a flushing oil (or light engine oil). This will remove the residual lubri­cant and foreign matter. Do not use water, steam,
kerosene or gasoline for flushing. (6) Scrape the residual gasket from the housing
and cover mating surfaces. Clean the mating sur­
faces with mineral spirits. Install a new cover gas­
ket. Apply a bead of MOPAR® Silicone Rubber Sealant on the housing cover (Fig. 2). Allow the
sealant to cure for a few minutes.

SEALING

SURFACE
CONTOUR
OF
BEAD
BEAD

THICKNESS

6.35mm (1/4
J9302-30

Fig.
2 Sealant On
Housing
Cover

Install the housing cover within 5 minutes af­
ter applying the sealant. If not installed the seal­ ant must be removed and another bead applied. (7) Install the cover on the differential with the

bolts.
Install the identification tag. Tighten the cover
bolts to 47 Nnn (35 ft. lbs.) torque.

CAUTION:
Overfilling the
differential
can result in
the lubricant
foaming
and overheating.
(8) Refill the differential housing with the speci­
fied quantity of MOPAR® Hypoid Gear Lubricant. (9) Install the fill hole plug and tighten to 34 N«m
(25 ft. lbs.) torque. (10) Road test the vehicle.

PINION
SHAFT
SEAL

REMOVAL (1) Raise and support the vehicle.
(2) Mark the drive shaft yoke and pinion yoke for
installation alignment reference.
(3) Remove the drive shaft from the yoke.
(4) Rotate the pinion gear three or four times.
(5) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 3).
(6) Mark the positions of the yoke and pinion gear
for installation alignment reference.

SPECIAL
TOOL
C-3281

SPECIAL
TOOL
C-452
J9102-31

Fig.
3
Pinion
Yoke
Removal

(7) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 5) use In­
staller C-3719-A and Handle C-4735
(2) Align the installation reference marks and po­
sition the yoke on the pinion gear.
(3) Install the pinion yoke, washer, and nut on
shaft. Tighten the nut to 339-366 N-m (250-270 ft.
lbs.) torque (Fig. 6).
(4) Align the installation reference marks and at­
tach the drive shaft to the yoke. (5) Add API grade GL 5 hypoid gear lubricant to