1993 DODGE TRUCK Service Repair Manual

3
- 42
REAR
SUSPENSION
AND
AXLE

SPECIAL TOOL
D-111
PRESS

DRIVE

PINION GEAR
SHAFT
REAR BEARING"
INSTALLATION

TOOL
SPECIAL
TOOL
C-4171 J9203-65 DRIVE
PINION GEAR
OIL

SLINGER

J9302-68

Fig.
33
Pinion
Rear Bearing Cup
installation
Fig.
35
Pinion
Rear Bearing
Installation

BEARING
CUP

INSTALLATION
TOOL
C-4203
DRIVER

HANDLE
TOOL

C-4171
SPECIAL

TOOL
C-3718
DIFFERENTIAL

HOUSING

SPECIAL
TOOL

C-3281

Fig.
34
Pinion
Front Bearing Cup
Installation
(13) Tighten the yoke nut to 339-366 N-m (250-270
ft. lbs.) torque. (14) Check bearing preload torque with an inch
pound torque wrench (Fig. 37). The torque necessary
to rotate the pinion gear should be;
• Original Bearings — 1-3 Nnn (10-20 in. lbs.)
• New Bearings — 2-5 Nnn (20-40 in. lbs.)
If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.

38);

• Increase the preload torque, decrease the shim
thickness
• Decrease the preload torque, increase the shim
thickness
J9103-21

Fig.
36
Pinion
Yoke
Installation

(15) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 39).
(16) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 40);
© Model 60 use Installer C-3719-A and Handle C-4735
• Model 70 use Installer C-359 and Handle C-4735 (17) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 36).

•

Fig.
37 Rotating
Pinion
Gear

Fig.
38
Shim
Locations
(18) Install a new yoke nut and tighten to 339-366
Nnn (250-270 ft. lbs.) torque.

PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH
TOOL
SET
C-758-D6 The alternate measurement and adjustment proce­
dure involves using Pinion Depth Measurement Gauge Set C-758-D6 (Fig. 41). (1) Install the pinion rear bearing cup (Fig. 42);
• Model 60 use Installer D-lll and Handle C-4171
• Model 70 use Installer C-4204 and Handle C-4171 Ensure the cup is correctly seated. (2) Install the pinion front bearing cup with In­
staller C-4203 and Handle C-4171 (Fig. 43).
REAR
SUSPENSION
AND
AXLE
3 - 43
C-452
J9102-31
Fig.
39
Pinion
Yoke
Removal

SPECIAL
TOOL
C-4735

J9203-56

Fig.
40
Pinion
Seal
Installation
Assemble C-758-D6 Tool Set as described (Fig.

41);
• Position Spacer (SP-5814 for Model 60) or (SP-5587
for Model 70) over Shaft (SP-526)
• Position pinion rear bearing on shaft • Position tools (with bearing) in the housing
• Install pinion front bearing
• Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533) (3) Prevent compression sleeve tool from turning
with Wrench C-3281.
Tighten the nut to seat the pinion bearings in the
housing (Fig. 44). Allow the sleeve to turn several times during the tightening to prevent brinelling the
bearing cups or the bearings.

3
- 44
REAR SUSPENSION
AND
AXLE
— __—_ . _ •

SPECIAL
TOOL
SET
Fig.
41
Pinion
Adjustment Tools
SPECIAL
TOOL

C-4171
J9203-65
Fig.
42
Pinion
Rear Bearing Cup
Installation

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.
(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 1-3 N-m (15-25 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. Center the arbor in cradles so equal space exists at
both ends. Position the bearing caps on the arbor
BEARING
CUP DRIVER
INSTALLATION
TOOL
C-4203
HANDLE
Fig.
44 Seating
Pinion
Bearings
tool. Install the attaching bolts. Tighten the cap bolts
to 14 N-m (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 45). The depth shim(s)
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
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. 46),
* Model 60 use Remover D-162 and Handle C-4171 *> Model 70 use Remover D-159 and Handle C-4171

•

REAR
SUSPENSION
AND
AXLE
3 - 4S

SPACER

DEPTH SHIMS
HERE
REAR
PINION

BEARING

SHAFT

BEARING
CAP ARBOR
J9203-53
Fig.
45 Depth
Shim(s)
Selection

HAMMER
DRIVER HANDLE
J9203-58

Fig.
46 Rear Bearing Cup
Removal

(11) Position depth shims in housing rear bearing
cup bore.
(12) Install the pinion rear bearing cup (Fig. 42);
• Model 60 use Installer D-lll and Handle C-4171
• Model 70 use Installer C-4204 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 C-3095-A until
completely seated (Fig. 47).
(15) Install pinion in housing bore.
(16) Assemble preload shims onto pinion and in­
stall the pinion gear in housing.
PRESS

DRIVE

PINION GEAR
SHAFT

REAR
BEARING
^
INSTALLATION
TOOL

DRIVE

PINION GEAR OIL

SUNGER

J9302-68

Fig.
47
Pinion
Rear Bearing
Installation
(17) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer
C-3718 and Wrench C-3281 (Fig. 48).

SPECIAL
TOOL

C-3718
DIFFERENTIAL
HOUSING

SPECIAL
TOOL

C-3281

J9103-21

Fig.
48
Pinion
Yoke
Installation

(18) Tighten the yoke nut to 339-366 Nnn (250-270
ft. lbs.) torque.
(19) Check bearing preload torque with an inch
pound torque wrench (Fig. 49). The torque necessary to rotate the pinion gear should be;
• Original Bearings — 1-3 Nnn (10-20 in. lbs.)
• New Bearings — 2-5 Nnn (20-40 in. lbs.)

3
- 48
REAR SUSPENSION
AND
AXLE
Fig.
49 Rotating
Pinion
Gear If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig. 50);
• Increase the preload torque, decrease the shim
thickness
• Decrease the preload torque, increase the shim
thickness

Fig.
50
Shim
Locations

(20) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 51).
(21) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 52); •
C-452
J9102-31
Fig.
51
Pinion
Yoke
Removal

• Model 60 use Installer C-3719-A and Handle C-4735
• Model 70 use Installer C-359 and Handle C-4735

SPECIAL
TOOL
C-4735

J9203-56

Fig.
52
Pinion
Seal
Installation
(22) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 53). (23) Install a new yoke nut and tighten to 339-366
N-m (250-270 ft. lbs.) torque.

RING GEAR BACKLASH
ADJUSTMENT
(1) Place Master Differential Bearing D-343
(D-117) on the case hubs (Fig. 24).
(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. 54). Ensure ring and pinion gear teeth are
tightly meshed. Zero the indicator.

•

REAR SUSPENSION
AND
AXLE
3 - 47

SPECIAL DIFFERENTIAL
TOOL
HOUSING

J9103-21

Fig.
53
Pinion
Yoke
installation
Fig.
54
Ring
Gear
Backlash
Measurement
(3) Insert
a
small
pry bar
between
the
bearing
cap

and right side
of
differential case.
Pry the
case
as far

as possible
to
left side
(Fig. 19).
Zero
the
dial indica­
tor pointer.
(4) Repeat
the
measurement several times
to
check
consistency. Record
the
travel distance.
The measurement above shows shim thickness
necessary
to
eliminate ring gear backlash. Sub­ tract 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. (8) Position
the
backlash shims (with determined
thickness)
on
case
hub
(ring gear side). Install bear­ ing
on the hub;

• Model
60 use
Installer C-4025-A
and
Handle
C-4171
(Fig. 55)

• Model
70 HD use
Installer C-4190
and
Handle
C-4171

Fig.
55
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.
(10) Install bearing
on hub;

• Model
60 use
Installer C-4025-A
and
Handle
C-4171
(Fig. 55)

• Model
70 HD use
Installer C-4190
and
Handle
C-4171 (11) Match each bearing
cup
with bearing (origi­

nal).
Install
the
cups
on the
bearings. (12) Position Spreader
D-167
with
the
tool dowel
pins seated
in the
locating holes
(Fig. 56).
Install
the

holddown clamps
and
tighten
the
tool turnbuckle fin­ ger-tight.
(13) Install
a
pilot stud
at the
left side
of the dif­

ferential housing. Attach Dial Indicator
to
housing

3
- 48
REAR
SUSPENSION
AND
AXLE

•

SPECIAL
TOOL

.MODEL
44-W-129-A
MODEL
60-D-167 (18) Rotate the assembly several revolutions to
seat bearings. Measure backlash at three equally
spaced locations with a dial indicator (Fig. 58).

Fig.
56
Differential
Housing
Separation pilot stud. Load the indicator plunger against the op­
posite side of the housing (Fig. 56) 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.

(14) 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.
(15) Remove the dial indicator.
(16) Install case in the housing. Ensure the differ­
ential bearings are fully seated. Remove the spreader.
(17) Observe the assembly reference marks and po­
sition the bearing caps at their original locations
(Fig. 57). Tighten the bearing cap bolts to 95-122
N*m (70-90 ft. lbs.) torque.
INSTALLATION

EFERENCE
LETTERS
TOOL

C-3339
8903-31

©
^
J9003-92

Fig.
57
Differential
Bearing Cap Reference Letters
Fig.
58
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. (19) 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
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.
(1) Apply a thin coat of hydrated ferric oxide, to
the drive and coast side of 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. 59)
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.

•
REAR SUSPENSION AND AXLE 3 - 49

DRIVE SIDE OF RING
GEAR TEETH
HEE^^^^^^^TOE COAST SIDE
OF RING
GEAR TEETH
TOE^^^^^^^^^EL 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.

J9003-24
Fig. 59 Gear
Teeth
Contact
Patterns