1993 DODGE TRUCK Service Repair Manual

2
- 52
FRONT
SUSPENSION
AND
AXLE

•

PINION
SEAL
J9203-55
Fig. 4 Seal Removal

SPECIAL TOOL
G4735

J9203-56

Fig. 5 Pinion Seal Installation the differential housing, if necessary.

(6)
Lower the vehicle.

LOCKING HUBS, SPINDLE AND AXLE SHAFT

REM0VAL/D1SASSEMBL
Y
(1) Raise and support the front of vehicle. (2) Remove the wheel/tire.
(3) Remove the brake caliper, refer to Group 5,
Brakes. Support the caliper to the frame structure
with wire. DIFFERENTIAL
Fig. 6 Tightening Pinion Shaft Nut
(4) Remove the allen-head screws that retain the
cap to the hub (Fig. 7).
Fig. 7 Allen-Head Screw Removal (5) Remove the snap ring retaining the axle shaft
in the hub (Fig. 8).

(6)
Remove the lock ring from the groove in the
hub (Fig. 9).
(7) Install two allen-head screws in hub locking
body (to assist in removal). Remove the hub locking
body assembly from the hub (Fig. 10).

• ___— . ^
FRONT
SUSPENSION
AND
AXLE
2 - 53

SCREWDRIVER
J9202-70
Fig.
9
Lock
Ring
Removal
(8) Remove the wheel bearing outer lock nut from
the spindle with Wrench 7158 (Fig. 11). Remove the
tabbed lock washer from the spindle.
(9) Remove the wheel bearing inner lock nut ring
from the spindle with Wrench 7158 (Fig. 11).
(10) Remove the hub and rotor assembly from the
spindle.
(11) Remove the nuts that attach the spindle to
the steering knuckle. Remove the spindle from the knuckle, use a soft faced mallet if necessary to tap
loose (Fig. 12).
SNAP
HUB
LOCKING
PRESSURE
CLUTCH
SNAP

RING
SEAL
CAP
J9202-71
Fig.
10
Locking
Hub
Components

Fig.
11
Lock
Nut
Ring
Removal
(12) Pull the axle shaft (with spacer, seal and
slinger) from the steering knuckle (Fig. 13).
(13) Clamp the spindle in a soft-jawed vise. Do not
clamp at the bearing contact surfaces. Remove the
bearing seal.
(14) Use Puller D-131 to remove needle bearings
from the spindle (Fig. 14).

ASSEMBL
Y/INSTALLA
TION

(1) Install needle bearing in the spindle with In­
staller C-4370 and Handle C-4171 (Fig. 15).

2
- 54
FRONT SUSPENSION
AND
AXLE
Fig.
12 Spindle Removal
SEAL
J9202-73

Fig.
13 Axle Shaft Removal

Fig.
14
Spindle
Needle Bearing
Removal

(2) Install a new spindle seal with Installer C-4373
and Handle C-4171 (Fig. 16).
(3) Install the seal with lip facing the axle shaft
splines (Fig. 17). Lubricate the seal (Fig. 18) with
Wheel Bearing Grease lubricant (NLGI Grade 2, EP
or an equivalent lubricant). •

Fig.
15
Spindle
Needle Bearing
Installation
Fig.
16
Spindle
Seal
Installation

(4) Carefully install the axle shaft through the
knuckle into the axle housing. Ensure the axle shaft splines are engaged with the differential side gears.
(5) Install the spacer on the axle shaft end.
(6) Install the brake splash shield and brake cali­
per support bracket.
(7) Install the splash shield and spindle on the
steering knuckle. Install the nuts and tighten to 81- 108 N-m (60-80 ft. lbs.) torque (Fig. 19).

•

Fig.
17 Axle Shaft
Seal
Installation

Fig.
19
Spindle
Installation
(8) Install the hub and rotor assembly on the spin­

dle.
Add Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant) to the bear­

ings.
FRONT
SUSPENSION
AND
AXLE
2 - 51

Fig.
20 Bearing Cap
Removal
(3) Use a mallet to drive the vertical yoke down­
ward to remove the upper needle bearing and cap (Fig. 20).
(4) Reverse the position of the yoke and remove op­
posite needle bearing and cap (Fig. 20). (9) Install the wheel bearing inner lock nut on the
spindle with Wrench 7158 (Fig. 11). Tighten the lock
nut to 68 N*m (50 ft. lbs.) to seat the bearings. (10) Loosen the inner lock nut. Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rotating the hub and
rotor assembly.
(11) Back off the inner lock nut 135-150 degrees to
set the free play.
(12) Install the tabbed lock washer in the nearest
hole in the washer. Install and tighten the outer lock nut with Wrench 7158 (Fig. 11) to 217-278 N-m (160-205 ft. lbs.) torque. The end play after the final bear­
ing adjustment should be within 0.001 inch to 0.010 inch (0.03 to 0.25 mm).
(13) Install the locking body assembly in the hub.
(14) Install the lock ring in the groove in the hub.
Ensure the ring is seated. (15) Install the snap ring on the end of the axle
shaft. Ensure the snap ring is seated.
(16) Install the cap onto the hub. Ensure the seal
is in place and not distorted.
(17) Install and tighten the allen-head screws to
4-5 N-m (35-45 in. lbs.) torque.
(18) Install the brake caliper, refer to Group 5,
Brakes. (19) Install the wheel and tire, refer to Wheel and
Tire Installation within this section. Lower the vehicle.

AXLE SHAFT AND
U-JOINT
SERVICE DISASSEMBLY
(1) Remove the snap rings from the yokes.
(2) Position the U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.

2
- 56
FRONT
SUSPENSION
AND
AXLE

Fig. 21 Bearing Cap installation (3) Remove the yoke from the vise and insert one
end of the spider into the bearing. Insert opposite
bearing and cap in the yoke arm bore by hand and align it with the spider.
(4) Place the yoke in a vise and press the cap into
the yoke arm bore and onto the spider (Fig. 22).

(5)
Use a short plug or a socket wrench to force the
bearing cap into the correct position and install the snap ring.
(6) Repeat the instructions in steps 1 through 5 for
installing remaining bearings, caps and yoke.

STEERING
KNUCKLE, UPPER AND LOWER KINGPINS

REMOVAL
(1) Remove axle shaft, refer to Axle Shaft And
U-Joint Service. (2) Remove the steering knuckle upper cap (Fig.

23).
(3) Remove the spring and retainer (Fig. 24). Dis­
card the gasket. •
Fig. 22 Bearing Cap & Spider Installation
Fig. 23 Upper Cap Removal (4) Remove the steering knuckle lower cap (Fig.

25).

(5) Dislodge the cap from the steering knuckle and
yoke.
(6) Remove the tapered bushing from the top of the
kingpin in the knuckle (Fig. 26). Remove the knuckle.
(7) Use Remover/Installer D-192 to remove the up­
per kingpin (Fig, 27). Discard the seal.
(8) Use Tool C-4212-1, C-4366-1 and C-4366-2 to
remove lower ball socket from lower arm bore (Fig.
28).
Discard the grease seal, retainer and lower bear­
ing cup.

(5)
Remove the yoke from the spider.
(6) Position the open ends of the spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove remaining bearings and caps.
(7) Remove the spider from the yoke.
(8) Clean and inspect all the components. Clean
any rust from the axle shaft splines. Retain each
bearing and cap separate. If any component is exces­ sively worn or damaged, replace the U-joint.

ASSEMBLY
(1) Insert the needle bearing and cap in one yoke
arm bore.
(2) Place the yoke in a vise (Fig. 21) and press the
needle bearing and cap into position. Install the snap
ring.

•

FRONT
SUSPENSION
AND
AXLE
2 - 57

Fig.
24
Spring
and Retainer
Removal

LOWER KINGPIN
AND
RETAINER
CAP
^
J9202-51

Fig.
25
Lower
Cap
Removal

INSTALLATION (1) Apply sealant to the mating surface of the
grease retainer. Lubricate the lower ball socket with
MOPAR Multi-Mileage Lubricant (or equivalent).
(2) Install the grease retainer in the yoke bore
with the concave side facing the upper kingpin.
(3) Use Remover/Installer C-4212-L, C-4366-3, and
C-4366-4 (Fig. 29) to install a new grease seal and
lower bearing cup.
(4) Fill the area in grease retainer with specified
grease, grease bearing cone and install. Install new
king pin bearing oil seal. Reposition Tools C-4212-L,
TAPERED
BUSHING
J9202-53

Fig.
26 Tapered
Bushing
Removal
J9202-66

Fig.
27 Upper
Kingpin
Removal
C-4366-3 and C-4366-5 (Fig. 30) and press the lower
bearing cup and seal into yoke lower arm bore.
(5) Use Remover/Installer D-192 to install the up­
per kingpin (Fig. 31). Tighten the kingpin to 668-813 N-m (500-600 ft. lbs.) torque. Install the seal over the
kingpin.
(6) Install the knuckle on the axle yoke.
(7) Insert the tapered bushing over the upper king
pin (Fig. 32).
(8) Fill the socket lower cavity with MOPAR
Multi-Mileage Lubricant (or equivalent). Install the
lower king pin and retainer cap on the steering
knuckle (Fig. 33). Install the capscrews and tighten
to 95-122 N-m (70-90 ft. lbs.) torque.
(9) Install the retainer and compression spring on
the tapered bushing.

2
- 58
FRONT
SUSPENSION
AND
AXLE

•

C-4366-2
C-4366-1
RH432A
C-4212-L

Fig.
28
Lower
Ball
Socket
Removal

C-4212-L

C-4366-3
C-4366-4

RH433A

Fig.
29
Lower
Bearing Cup Installation
(10) Install a new gasket over the steering knuckle
upper studs. Install the upper cap (and steering arm
C-4212-L

C-4366-3

RH434A

Fig.
30
Lower
Bearing &
Seal
Installation
TORQUE

WRENCH

SEAL
J9202-66

Fig.
31 Upper
Kingpin
Installation
on the left side). Install the bolts/nuts and tighten to
96-122 N*m (70-90 ft. lbs.) torque. (11) Lubricate the upper and lower king pin
through the fittings with MOPAR Multi-Mileage Lu­
bricant (or equivalent).

•

TAPERED

BUSHING

J9202-53

Fig.
32 Tapered
Bushing
Installation

J9202-52

Fig.
33
Lower
King
Pin and Retainer
Installation
(12) Install the axle shaft, refer to Axle Shaft and
U-Joint Installation.

COMPLETE
AXLE REMOVAL/INSTALLATION SERVICE
INFORMATION
It is not necessary to remove the complete front
axle from the vehicle for routine service. If the hous­
ing or axle shaft tubes are damaged, the complete axle can be removed and installed via the following
procedures.

REMOVAL
(1) Block the brake pedal in the up position. Raise
and support the vehicle at a comfortable working
height.
(2) Remove the front wheels/tires.
FRONT SUSPENSION
AND
AXLE
2 - 59
(3) Mark the front drive shaft and the pinion yoke
for installation alignment reference.
(4) Disconnect the front drive shaft from the axle
yoke. Attach the drive shaft to the frame rail with
wire.

(5) Remove the cotter pin, the nut, and disconnect
the drag link from the steering knuckle arm (left side only). Discard the cotter pin.
(6) Disconnect flexible brake fluid hose fittings at
the frame crossmember. Plug the hoses at the fit­

tings.
(7) Remove the shock absorber lower nut and stud
from the axle shaft tube bracket. Remove the nuts and disconnect the stabilizer bar links from the
spring brackets. (8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve­
hicle.
INSTALLATION (1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group. (3) Install the shock absorber. Refer to Front Sus­
pension—4 WD Vehicles within this group.
(4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension—4WD Vehicles within this group.
(5) Remove plugs and connect the brake hose fit­

tings.
Refer to Group 5, Brakes. (6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering. (7) Connect the drive shaft to the pinion yoke with
the installation reference marks aligned. Install the
washers and the nuts and tighten to 19 N-m (14 ft. lbs.) torque.
(8) Remove the supports, lower the vehicle and re­
move the block from the brake pedal.
(9) Raise the vehicle.
• Bleed and adjust the brakes
• Lubricate all the ball stud fittings
• Inspect the differential housing lubricant level. Re­
fer to Group 0, Lubrication and Maintenance.
(10) Lower the vehicle and test the axle and sus­
pension operation.

DIFFERENTIAL DISASSEMBLY
REMOVAL/DISASSEMBLY
(1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 34).
(2) Remove the differential bearing caps.