1993 DODGE TRUCK Service Repair Manual

3-18 REAR SUSPENSION
AND
AXLE

• remove the shaft and front bearing. This will dam­
age the front bearing rollers and bearing cup.
The front bearing and cup must be replaced. Discard the bearing collapsible spacer.
(4) Remove the front and rear bearing cups with
Remover C-4306 and Handle C-4171.
(5) Remove the rear bearing from the pinion shaft
with Puller C-293-PA and Adapter (Fig. 15). Remove and record the pinion gear depth shims.
• 8 3/8 use Adapter C-293-42 • 9 1/4 use Adapter C-293-37

SPECIAL
TOOL

C-293-PA

Fig. 15 Inner Bearing Removal
RING GEAR Do not remove the ring gear from case unless
the runout must be measured.
(1) Clamp the case (with the ring gear bolts facing
upward). Use a vise equipped with soft jaws (brass).
(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case

pilots.
Remove the ring gear.
CASE FLANGE RUNOUT MEASUREMENT (1) If the ring gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should also be mea­
sured. Install the case with the bearing cups and the
threaded adjusters close to their original position.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 (Fig. 12) to thread both adjusters inward. Remove all side play.
(3) Attach Dial Indicator to measure the flange
runout. The plunger should contact the ring squarely
between the outer edge and the gear attaching bolt holes (Fig. 16). Fig. 16 Case Flange Runout Measurement
(4) Rotate the differential case several times. Ob­
serve the dial indicator pointer. Mark the area of
maximum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). If the
runout exceeds the amount replace the differential
case.

You can reduce excessive ring gear runout by
positioning the ring gear runout mark 180 de­ grees opposite the flange runout mark.
(5) Remove the differential bearing cap bolts. Re­
move the differential case from the differential hous­ ing.
DIFFERENTIAL CASE DISASSEMBLY (1) Rotate the side gears until the pinion gears are
located at the differential case opening and remove
them.
(2) Remove the side gears and the thrust washers.
(3) Remove the differential bearings from the case
hubs with Puller C-293-PA, Adapter (Fig. 17).
• 8 3/8 use Adapter C-293-48 and Plug SP-3289
• 8 1/4 use Adapter C-293-48 and Plug C-293-3
CLEANING AND INSPECTION (1) Clean all of the differential components in
cleaning solvent. Allow the bearings to either air dry
or dry them with a lint-free cloth. Dry the other com­
ponents with compressed air.
(2) Examine each component for wear or damage.
(3) Replace shims, bearings and cups as a set only.
Replace bearings and cups if either is galled, worn,
cracked, or damaged.
(4) Inspect the differential side and pinion gears.
Replace any gear that is worn, cracked or chipped.
(5) Inspect the differential case. Replace the case if
cracked or damaged.
Polish each axle shaft with No. 600 crocus
cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft seal
contact surface. When polishing, the crocus

•

REAR
SUSPENSION
AND
AXLE
3 - 11

ADAPTERS
Fig.
17
Differential
Bearing
Removal
cloth should be moved around the circumfer­
ence of the shaft (not in-line with the shaft).
When replacing a drive pinion gear bearing,
always replace the bearing and cup as a
matched set only.
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them if necessary.
(7) Test each threaded adjuster to determine if it
rotates freely. (8) If an adjuster binds, repair the damaged
threads or replace the adjuster.

EXCITER
RING
REPLACEMENT
The ring gear must be removed before the RWAL
brake exciter ring can be replaced.
(1) Remove exciter ring with a hammer and drift.
(2) Heat the replacement exciter ring with a heat
lamp or by immersing in a hot fluid. The tempera­
ture should not exceed 149°C (300°F). Do not use a
torch to heat the ring.
(3) After heating, quickly position the exciter ring
on the differential case adjacent to the flange.

DIFFERENTIAL
CASE ASSEMBLY
(1) Lubricate all the differential case components
with gear lubricant. (2) Place the thrust washers on the differential
side gears. Position the gears in the differential case
counterbores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear­ ance Measurement And Adjustment.
(3) Position the thrust washers on the differential
pinion gears. Mesh the pinion gears with the side

gears.
Ensure that the pinion gears are exactly 180 degrees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align these components with the
mate shaft bores in the case.
(5) If the ring gear was removed, clean all contact
surfaces. Use an Arkansas stone or fine file to re­
move any sharp areas from the chamfered inside di­ ameter.
(6) If removed, heat ring gear with a heat lamp or
by immersing in a hot fluid. The temperature should not exceed 149°C (300°F). Do not use a torch to
heat the ring.
(7) Position heated gear on case. Use two equally
spaced Pilot Studs C-3288-B to align the gear with
the flange holes (Fig. 18).

J9203-24

Fig.
18
Case-To-Ring
Gear
Alignment

(8) Install replacement ring gear bolts (with left
hand threads). Alternately and evenly tighten each
bolt to 95 N-m (70 ft. lbs.) torque.

CAUTION:
When
installing a
differential
bearing,
never apply force to the bearing
cage
because
bear­

ing
damage
will
result.
(9) Place a differential bearing on each hub (Fig.

19).

• 8 3/8, use Installer C-4340 and Handle C-4171
• 9 1/4, use Installer C-4213 and Handle C-4171

3
- 20
REAR SUSPENSION
AND
AXLE

•

SPECIAL
TOOL
C-4171

SPECIAL
TOOL

8-3/8-
C-4340
9.1/4-
C-4213
J9203-33
Fig.
19 Differential Bearing Installation

PINION DEPTH MEASUREMENT AND ADJUSTMENT

WITH
GAUGE SET

(1) Use pinion gear adjustment gauge set and con­
tinue the assembly: • 8 3/8, use C-3715-B (Fig. 20)
• 9 1/4, use C-758-D6 (Fig. 21) (2) Install front (outer) bearing cup use Installer
D-130 and Handle C-4171. (3) Install rear (inner) bearing cup.
• 8 3/8 axles, use Installer C-4308 and Handle C-4171
• 9 1/4 axles, use Installer C-4310 and Handle C-4171 8 3/8 axles assemble C-3715-B Tool Set as de­
scribed (Fig. 20);
SPECIAL
TOOL
SET

G3715-B

SP-6030

SP-536—
SP-531
J9203-51

Fig.
20 8 3/8 Axle
Pinion
Adjustment Tools
• Position Spacer (SP-6030) over Shaft (SP-5385) • Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-5382)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193) 9 1/4 axles assemble C-758-D6 Tool Set as de­
scribed (Fig. 21);
SPECIAL TOOL C-758-D6
SP-6018

SP-536-*- Fig.
21 9 1/4 Axle
Pinion
Adjustment Tools and • Position Spacer (SP-6017) over Shaft (SP-526)
• Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-1730)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-535-A), Washer (SP-534)
Nut (SP-533) (4) Prevent compression sleeve tool from turning
with Wrench C-3281.
Tighten the nut to seat the pinion bearings in the
housing (Fig. 22). 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 the separation distance. The required thickness
of the depth shim(s) is determined according to
the following information. (5) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri­ cant. Re-tighten the compression nut tool to 1-3 N*m (15-25 in. lbs.) torque. Rotate the pinion gear several
complete revolutions to align the bearing rollers. (6) Install Gauge Block.
• 8 3/8 axles (Fig. 20)
• Install Gauge Block SP-5383 at the end of SP-5385
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531 • 9 1/4 axles (Fig. 21)

•

REAR SUSPENSION
AND
AXLE
3 - 21

Fig.
22 Seating Pinion
Bearings
• Install Gauge Block SP-6020 at the end of SP-526
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531
(7) Position Crossbore Arbor in the differential
housing.
• 8 3/8 (Fig. 20); (SP-6029)
• 9 1/4 (Fig. 21); (SP-6018)
(8) Center the tool. Place a piece of 0.002 inch
shim stock at each end of the arbor. Position the
bearing caps on the arbor tool. Install the attaching

bolts.
Tighten the cap bolts to 14 N*m (10 ft. lbs.) torque.
(9) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 23). The depth shim(s)
fit must be snug but not tight (drag friction of a
feeler gauge blade).
SPACER

BEARING
CAP
ARBOR
J9203-53 Fig.
23 Depth
Shim(s)
Selection Depth shims are available in 0.001-inch incre­
ments from 0.020 inch to 0.038 inch. (10) Note the etched number on the face of the
drive pinion gear (e.g., -0, -1, -2, +1, +2, etc.). The
numbers 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 from the thickness of the depth shim(s). If the
number is 0, no change is necessary.
(11) Remove the tools from the differential hous­
ing. (12) Position the depth shim(s) on the pinion gear.
Install the rear bearing (Fig. 24). Be sure the contact surfaces are clean and without foreign particles.
• 8 3/8 axles use Installer C-4040
PINION GEAR DEPTH
VARIANCE
Original Pinion

Gear
Depth Variance
Replacement
Pinion Gear Depth Variance

Original Pinion

Gear
Depth Variance
-4

-3
-2
-1

0
+
1

+2

+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
-0001 -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
J8902-46

3
- 22
REAR
SUSPENSION
AND
AXLE

• 9 1/4 axles use Installer C-3095

Fig.
24 Shaft Rear Bearing
Installation
(13) Lubricate the pinion gear front and rear bear­
ings with gear lubricant.
(14) Install the pinion gear in the housing. Install
the new collapsible spacer at the end of the pinion gear. Install the pinion gear front bearing.
(15) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281 (Fig. 23).
It is necessary to use the tools (above) to cor­
rectly seat the front bearing on the drive pinion gear shaft (Fig. 25).

CAUTION:
Use
care
to
prevent collapsing preload

collapsible
spacer during installation
of the
yoke

and
seating
the
front bearing.

(16) Remove yoke and tools from the pinion gear.
(17) Install the new pinion gear shaft seal (Fig.

26).

• 8 3/8-inch diameter use Seal Installer C-4076-A and Handle C-4735-1
• 9
1/4-inch
diameter use Seal Installer C-3980-A or C-4109-A and Handle C-4735 The seal is correctly installed when the seal
flange contacts the face of the differential hous­
ing flange.
The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of sealant is not required. (18) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281.
(19) Remove the tools. Install the Belleville
washer. The convex side of the washer must face out­ ward. Install the pinion nut. 4

J9103-21

Fig.
25
Pinion
Yoke
Installation

Fig.
26
Pinion
Gear
Seal
Installation
(20) Retain pinion yoke with Wrench C-3281. Ini­
tially tighten the drive pinion gear shaft nut enough
to remove the bearing end play. While tightening, ro­
tate the pinion shaft to ensure the bearing rollers are correctly seated. (21) Tighten the pinion nut to (Fig. 27) 285 N*m
(210 ft. lbs.) torque (minimum). (22) Remove the tools from the shaft. Rotate the
pinion several complete revolutions (both directions)
to additionally seat the bearing rollers.

CAUTION:
Never loosen
the
pinion gear
nut to de­

crease
the
pinion gear bearing preload torque.
If the

specified preload torque
is
exceeded,
a
replacement

collapsible
spacer must
be
installed.
The
torque
se­

quence
will
have
to be
repeated.
SPECIAL
DIFFERENTIAL

TOOL
HOUSING

•

REAR SUSPENSION
AND
AXLE
3 - 23
Fig. 27 Tightening Pinion Gear Nut (23) Measure the pinion bearing preload torque by
rotating pinion shaft with a Newton-meter or an inch-pound torque wrench. The correct bearing pre­load torque is 2-4 N-m (20-30 in. lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a minimum of 285 N-m (210 ft. lbs.)
torque (Fig. 28).
When using original pinion rear bearing and a
replacement front bearing. The correct preload torque is 1 N-m (10 in. lbs.) torque in addition to
the torque measured and recorded during disas­ sembly. Fig. 28 Bearing Preload Torque Measurement
The bearing preload torque should be constant
during a complete revolution of the drive pinion
gear shaft. If the preload torque varies during rotation of the shaft, there is an internal binding
that must be corrected before final assembly.
(24) If the specified torque is not obtained, tighten
the nut in small increments until the preload torque is obtained.
The differential will be unacceptable for use if
the final nut torque is less than 285 N-m (210 ft.
lbs.) torque. If the preload torque is not within the specified range this is also unacceptable.
DIFFERENTIAL CASE INSTALLATION (1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups and threaded ad­
justers. A dab of grease can be used to keep the ad­
justers in position. Carefully position the assembled differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations (Fig. 29).
Fig.
29 Bearing
Caps
&
Bolts

(3) Install the bearing cap bolts (Fig. 29). Tighten
the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten the lower bolts finger-tight until the bolt head is lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING GEAR BACKLASH ADJUSTMENT The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed dur­
ing all backlash measurements
• Maintain the torque while adjusting the bearing
preload and ring gear backlash • Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise

3
- 24
REAR SUSPENSION
AND
AXLE
Fig.
30 Threaded Adjuster Tool
(2) Install Dial Indicator (Fig. 31). Position the
plunger against the drive side of a ring gear tooth. Measure the backlash at 4 positions (90 degrees apart) around the ring gear. Locate and mark the
area of minimum backlash.
(3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
measurements will be taken with the same gear
teeth meshed.
(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.003 to 0.004
inch (0.076 to 0.102 mm) with each adjuster tight­
ened to 14 N-m (10 ft. lbs.) torque. Seat the bearing
cups with the procedure described above.
(5) Tighten the differential bearing cap bolts;
• 8 3/8 axles to 95 N-m (70 ft. lbs.) torque
• 9 1/4 axles to 136 N-m (100 ft. lbs.) torque
(6) Use Wrench C-4164 to tighten the right-side
threaded adjuster to 102 N-m (75 ft. lbs.) torque. Seat the bearing cups with the procedure described above. •

Fig.
31
Ring
Gear
Backlash
Measurement Continue to tighten the right-side adjuster and seat
bearing cups until the torque remains constant at 102 N-m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is ob­ tained.
The left-side threaded adjuster torque should
have approximately 102 N-m (75 ft. lbs.) torque. If the torque is considerably less, the complete adjustment procedure must be repeated. (8) Tighten the left-side threaded adjuster until
102 N-m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above. Do this until the torque remains constant. (9) Install the threaded adjuster locks . Ensure the
lock finger is engaged with the adjuster hole.
Tighten the lock screws to 10 N-m (90 in. lbs.) torque.
SIDE
GEAR CLEARANCE
MEASUREMENT
AND

ADJUSTMENT

When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install the axle shafts and C-clip locks and pin­
ion mate shaft. If necessary, refer to the installation
located within this group. (2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub (Fig. 32).
(3) If side gear clearances is no more than 0,005
inch. Determine if the shaft is contacting the pinion
gear mate shaft. Do not remove the feeler gauges,
inspect the axle shaft with the feeler gauge in­ serted behind the side gear. If the end of the axle
shaft is not contacting the pinion gear mate shaft,
the side gear clearance is acceptable.
• Insufficient adjuster torque will not support the
ring gear correctly and can cause excessive differen­
tial case free-play and ring gear noise
The differential bearing cups will not always
immediately follow the threaded adjusters as they are moved during adjustment. Ensure accu­
rate bearing cup responses to the adjustments. Maintain the gear teeth engaged (meshed) as
marked. The bearings must be seated by rapidly
rotating the pinion gear a half turn back and forth. Do this five to ten times each time the
threaded adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded ad­
juster inward (Fig. 30). Adjust until the differential bearing free-play is eliminated. Allow some ring gear
backlash (approximately 0.01 inch/0.25 mm) between
the ring and pinion gear. Seat the bearing cups with
the procedure described above.

REAR
SUSPENSION
AND
AXLE
3 - 2§

Fig.
32
Side
Gear Clearance Measurement
(4)
If
clearance
is
more than 0.005 inch (axle shaft
not contacting mate shaft), record
the
side gear clear­
ance.
Remove
the
thrust washer
and
measure
its

thickness with
a
micrometer.
Add the
washer thick­ ness
to the
recorded side gear clearance.
The sum of

gear clearance
and
washer thickness will determine
required thickness
of
replacement thrust washer (Fig.
33).
SIDE GEAR CLEARANCE
0.007

THRUST
WASHER THICKNESS
+ 0.033
TOTAL
0.040
I ^ ^ 0.040

REPLACEMENT WASHER THICKNESS
- 0.037
NEW SIDE GEAR CLEARANCE
0.003
J9203-31

Fig.
33
Side
Gear Calculations
In some cases,
the end of the
axle shaft will move
and contact
the
mate shaft when
the
feeler gauge
is

inserted.
The
C-clip lock
is
preventing
the
side gear
from sliding
on the
axle shaft.
(5)
If
there
is no
side gear clearance, remove
the

C-clip lock from
the
axle shaft.
Use a
micrometer
to
measure
the
thrust washer thickness. Record
the

thickness
and
re-install
the
thrust washer. Assemble
the differential case without
the
C-clip lock installed and re-measure
the
side gear clearance.
(6) Compare both clearance measurements.
If the

difference
is
less than
0,012
inch (0.305
mm), add
clearance recorded when
the
C-clip lock
was
installed
to thrust washer thickness measured.
The sum
will determine
the
required thickness
of the
replacement
thrust washer.
(7)
If
clearance
is 0.012
inch (0.305
mm) or

greater, both side gears must
be
replaced (matched set)
and the
clearance measurements repeated.
(8)
If
clearance (above) continues
to be 0.012
inch
(0.305
mm) or
greater,
the
case must
be
replaced.

RING
GEAR
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.
• Excessive backlash
is
corrected
by
moving
the
ring gear teeth closer
to the
pinion gear teeth
• Insufficient backlash
is
corrected
by
moving
the

ring gear away from
the
pinion gear
(1) Apply yellow ferrous (iron) oxide compound
to

both drive
and
coast sides
of
ring gear teeth. (2) Rotate
the
ring gear
one
complete revolution
in

both directions.
(3) Note patterns
in
compound. Refer
to (Fig. 34)

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.
(6) Install
the
RWAL brake speed sensor
and
cover
onto
the
axle housing. Tighten
the
sensor
to 24 N*m
(18
ft. lbs.)
torque.