1993 DODGE TRUCK Service Repair Manual

3
- 50
REAR
SUSPENSION
AND
AXLE

• (6)
Install
the
RWAL brake
speed
sensor
and
cover

onto
the
axle
housing.
Tighten
the
sensor
to 24 Nsm (18 ft. lbs.)
torque.

SPECIFICATIONS
REAR
AXLE MODEL 60 AND 70
Axle Type ......................
Full-Floating
Hypoid

Application
D-TRK
Ring
Gear Diameter Model 60. ............ .
.24.76
cm (9.75 in.)
Model 70 .................... .
.26.67
cm (10.5 in.)
Lubricants
MOPAR
Gear
Lubricant
or
equivalent
SAE
75W-90,

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

Differential
Model 60 .... . Standard/Track-Lok
Model 70 Standard/Powr-Lok

Lubricant
Capacity Model 60 .....
2.84L
(6.0 pts) Model 70 .3.31L (7.0 pts)
Axle Model M 60, M 70 Axle Ratio to 1 Model 60
.4.10,
4.56
Model
70......
3.07, 3.54,
4.10,4.56

Track Model 60 . 64.0 in.
Model 70
w/dual
rear
wheels. ....... .73.0 in., 68.0 in. w/single
rear
wheels ............. .64.0 in.
GAWR
(lbs.)

Mode
60
5800,
6200

Mode
70.
6900*,
7500*,
6200

*denotes dual
rear
wheels

Differential
Bearing Preload
Shim.
0.38 mm
(0.015
in.)

Differential
Side
Gear
to
Case
Clearance
.0.00-0.18
mm
(0.000-0.007
in.)

Ring
Gear
Backlash
.....
.0.12-0.20
mm
(0.005-0.008
in.)
Drive Pinion Gear Bearing Breakaway Preload Torque
Original Bearings 1.2 N-m
(10-20
in. lbs.) Replacement Bearings 2-5 N-m
(20-40
in. lbs.)
Drive Pinion Gear Depth ................. Select
Shims

Standard
Setting Model 60 ...
.79.37
mm
(3.125
in.)
Model 70 .
88.90
mm (3.50 in.)

Side
Gear Clearance (max.) 0.015 mm
(0.006
in.)

Case
Runout (max.)
.0.015
mm
(0.006
in.)

J9302-77

REAR
SUSPENSION
AND
AXLE
3 - 51

TRAC-LOK
DIFFERENTIAL

SERVICE
INFORMATION
Model
60 rear
axles equipped
with
Trac-Lok
differ­
ential are optionally available for Ram Truck vehi­
cles.

DIFFERENTIAL
NOISE
Noise complaints involving Trac-Lok should be
evaluated to determine the source of the noise. If a noise occurs while the vehicle is turning, the proba­
ble cause is incorrect or insufficient gear lubricant. Replace the axle gear lubricant and add MOPAR Hy­
poid Gear Lubricant Additive. If the chatter persists, clutch disc damage could have occurred.

WARNING: WHEN SERVICING VEHICLES
WITH
A

TRAC-LOK DIFFERENTIAL,
DO NOT
USE
THE EN­
GINE
TO
ROTATE
THE
AXLE
AND
WHEELS.
BOTH
REAR
WHEELS MUST
BE
RAISED, FROM
THE
SUR­

FACE
AND THE
VEHICLE SUPPORTED. TRAC-LOK
CAN EXERT ENOUGH DRIVING FORCE
TO
CAUSE
THE VEHICLE
TO
MOVE.
(4) Place a block of wood that is 2 inches high and
a minimum of 3 inches wide in front of one of the
front tires.
(5) With a gradual throttle opening, attempt to
slowly drive the vehicle over the block of wood.
(6) If the Kraft paper slips out before the front
wheel moves over the block of wood; reposition the vehicle so paper and board are under the opposite
rear wheel. Attempt to drive over the block of wood
the second time.
(7) If the front wheel moves over the block of wood,
the axle can be considered to be functioning nor­ mally.

LUBRICANTS
The lubricant recommended for Trac-Lok differen­
tial is API grade GL 5. A container of Trac-Lok Lu­
bricant (friction modifier) should be added after service. Refer to Group 0, Lubrication and Maintenance for
additional information.

DIFFERENTIAL
TEST
(1) Drive the vehicle to thoroughly warm up the
lubricant in the rear axle. (2) Place a large piece of Kraft paper over a
smooth Formica board.
(3) Drive the vehicle over the Formica board until
one rear wheel/tire is in the center of the board and
paper.
COMPONENTS

The Trac-Lok (limited-slip) differential components
are illustrated in (Fig. 1). Refer to this illustration
during repair service for component detail and their
location.
DIFFERNTIAL

CASE
THRUST
WASHER

PINION
SNAP
RING
SHAFT
LOCK
PIN
CLUTCH PACK
PINION

MATE

SHAFT
J9203-13

Fig.
1
Trac-Lok
Differential

3
- 52
REAR SUSPENSION
AND
AXLE

DISASSEMBLY

Service to the Trac-Lok differential requires the
use of Tool Set C-4487 (J-23781). Refer to differential
overhaul in the Model 60 section for differential case
removal and installation. (1) Clamp one axle shaft in a vise (with protective
jaws) with the splined end upward (Fig. 2).
USE

AXLE

SHAFT

AS
HOLDING
FIXTURE
(EXTEND
NO
MORE
THAN
2
3/4 IN.)
J8903-42

~
Fig. 2 Axle Shaft As
Holding
Fixture

(2)
Place shop towels under the differential gear to
avoid gear damage during removal of the ring gear (Fig. 3).
RING GEAR
BOLTS UPWARD

DIFFERENTIAL ON AXLE
SHAFT
(3) Position the differential case on the axle shaft
(Fig. 3). (4) Remove and discard the ring gear bolts. They
are not reusable.
(5) Remove the case from the fixture. Remove the
ring gear from the case by tapping it with brass drift and a hammer.

(6)
Position the case on the fixture.
(7) Remove the pinion gear mate shaft retaining
roll pin (Fig. 4).

DIFFERENTIAL
CASE
PINION

GEAR
MATE SHAFT

PUNCH

LOCKPIN

J9003-95
Fig. 4
Pinion
Gear Mate Shaft
Lock
Pin
Removal
(8) Remove the pinion gear mate shaft. Use a ham­
mer and a brass drift and tap the shaft out.
(9)
Install and lubricate Step Plate C-4487-1 (Fig.

5).

SPECIAL
TOOL

C-4487-1
DIFFERENTIAL

CASE
LOWER

SIDE

GEAR
J9203-4

J8903-43
Fig.
5
Step
Plate
Tool
Installation

Fig.
3
Differential
Case
On Shaft

•

REAR SUSPENSION
AND
AXLE
3 - §3 (10) Assemble Threaded Adapter C-4487-3 into top
side gear. Thread forcing Screw C-4487-2 into
adapter until it becomes centered in adapter plate.
(11) Use a small screw driver, position it in slot of
Threaded Adapter C-4487-3 (Fig. 6). This will pre­
vent adapter from turning.
SOCKET
THREADED ADAPTER DISC

C-4487-3

THREADED ROD

C-4487-2
DISC

C-4487-1
J9203-1

Fig. 6 Threaded Adapter Installation (12) Tighten forcing screw tool enough to relieve
clutch pack tension. Remove both pinion thrust
washers (Fig. 7).

SPECIAL
TOOL

C-4487-2
(13) Loosen the forcing screw tool until the clutch
pack tension is relieved.
(14) Insert Turning Bar C-4487-4 in case. Rotate
case with tool until pinion gears can be removed (Fig. 8). Remove tools from the case.
THREADED
ROD

C-4487-2
SPlCIAL

tOOL

C-4487-4

J9203-2

Fig. 8 Pinion Gear Removal (15) Remove top side gear and clutch pack. Keep
plates in correct order during removal (Fig. 9).
(16) Remove case from fixture. Remove remaining
clutch pack.
SIDE GEAR
AND CLUTCH DISC PACK DIFFERENTIAL

CASE

PINION
GEAR
THRUST

WASHER FEELER
"GAUGE

33
X
/

J9203-3

Fig. 7 Remove Pinion Thrust Washer
RETAINER

SPECIAL
TOOL

C-4487-1 J9203-5

Fig. 9 Side Gear & Clutch Disc Removal (17) Remove clutch pack retaining clips. Mark
each clutch pack for installation reference.

3
- 54
REAR SUSPENSION
AID
AXLE

•
CLEANING AND INSPECTION

(1) Clean all components in cleaning solvent. Dry
components with compressed air. (2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo­
nent in either pack is damaged. (3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged. (4) Inspect differential case and pinion shaft. Re­
place if worn or damaged.

ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both packs must be replaced. Lubricate each com­
ponent with gear lube before assembly and installa­ tion. (2) Assemble the clutch discs into packs (Fig. 10).
(3) Secure disc packs with retaining clips (Fig. 10).
(4) Position assembled clutch disc packs on the
side gear hubs.
CLUTCH
PACK
RETAINER
J8903-50

Fig.
10
Clutch
Disc
Pack
(5) Position case on fixture (Fig. 3).
(6) Install clutch pack and side gear in lower bore
(Fig. 11). Be sure clutch pack retaining clips re­
main in position and are seated in the case
pockets.
(7) Install lubricated Step Plate C-4487-1 on first
clutch pack (Fig. 12). (8) Install the upper side gear and clutch disc pack
(Fig. 12).
(9) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear, insert forcing Screw C-4487-4 (Fig. 6).
Fig.
11
Clutch
Discs
&
Lower
Side
Gear
Installation

UPPER SIDE
GEAR AND
CLUTCH
DISC PACK
Installation

(10) Tighten forcing screw tool to compress clutch

discs.
(11) Install pinion gears. Rotate case with Turning
Bar C-4487-4. Make sure holes of pinion mate gears are aligned with case.

•

REAR
SUSPENSION
AND
AXLE
3 - 55
(12) Tighten forcing screw
to
compress
the
conned

plates.
Lubricate
and
install pinion gear thrust washers with
a
small screw driver.
(13) Insert and tap
the
pinion shaft into the differ­
ential case (Fig.
13).

(14) Secure pinion shaft with
new
roll pin. Stake
roll
pin
to
differential case.
Fig.
13
Pinion
Gear
Mate
Shaft
installation

POWER-LOK
DIFFERENTIAL

SERVICE
INFORMATION Model
70
rear axles equipped with
a
Power-Lok
differential
are
optionally available
for
Ram
Truck
vehicles (Fig.
1).

FLANGE
BUTTON
BOLTS

PINION

AAATE
SHAFT
J9203-71

Fig.
1
Power-Lok
Differential

DIFFERENTIAL
NOISE
Noise complaints involving
a
Power-Lok should
be

evaluated
to
determine
the
source
of
the noise.
If a

noise occurs while
the
vehicle
is
turning,
the
proba­
ble cause
is
incorrect gear lubricant. Replace axle gear lubricant
and add
MOPAR Hypoid Gear Lubri­
cant Additive. This will correct the condition
in
most
instances. However,
if the
chatter persists, clutch
disc damage could have occurred.

WARNING:
WHEN SERVICING VEHICLES
WITH
A
POWER-LOK
DIFFERENTIAL, DO NOT USE THE EN­

GINE
TO
ROTATE THE AXLE AND
WHEELS.
BOTH
REAR
WHEELS MUST BE
RAISED
FROM THE
SUR­

FACE
AND
THE
VEHICLE SUPPORTED. POWER-

LOK
CAN
EXERT ENOUGH DRIVING FORCE
(IF

ONE
WHEEL IS
IN
CONTACT
WITH
THE SURFACE)
TO
CAUSE
THE VEHICLE TO MOVE.

DIFFERENTIAL
TEST
(1) Drive
the
vehicle
to
thoroughly warm
up the

lubricant
in
the
rear axle.
(2) Place
a
large piece
of
Kraft paper over
a

smooth Formica board. Ensure Formica board
is on a

flat and level surface.
(3) Drive
the
vehicle over
the
Formica board until
one rear wheel
is in the
center
of
the board
and
pa­

per. (4) Place
a
block
of
wood that
is 2
inches high
and

a minimum
of 3
inches wide
in
front
of
one
of
the

front tires.
(5) With
a
gradual throttle opening, attempt
to

slowly drive
the
vehicle over
the
block
of
wood.
(6)
If
the Kraft paper slips out from under the rear
wheel before
the
front tire moves over
the
block
of
wood; reposition
the
vehicle
so
paper
and
board
are
under
the
opposite rear wheel. Attempt
to
drive over
the block
of
wood
the
second time.

3
- 56
REAR SUSPENSION
AND
AXLE
CLUTCH

PLATES

J9203-72
BUTTON

HALF

FLANGE
HALF
Fig.
2
Case
Marked
(7)
If the front wheel moves over the block of wood,
the axle can be considered to be functioning normally.

LUBRICANTS
The lubricant recommended for Power-Lok differ­
ential is API grade GL 5. A container of Trac-Lok
Lubricant (friction modifier) should be added after
service. Refer to Group 0, Lubrication and Maintenance for
additional information.
FLANGE
HALF
CLUTCH

RING
J9203-73

Fig.
3
Cover
Half
Removal

DISASSEMBLY

(1) Mark the ring gear half and cover half for in­
stallation reference (Fig. 2). (2) Remove the case attaching bolts and remove
the button cover half (Fig. 3). (3) Remove the pinion mate gear, side gear (clutch)
ring and clutch pack shaft (Fig. 4). Keep these parts with the button cover half for correct installation in
their original positions.
PINION MATE

GEAR

SCREW

PLATE
DISHED

DISC
PLATE

DISHED

DISC PINION AAATE
CROSS
SHAFT
BUTTON HALF

J9203-74

Fig.
4
Power-Lok
Components

•

REAR SUSPENSION
AND
AXLE
3 - 57 (4) Remove the same parts listed above from the
ring gear flange half of the case. (Fig. 4). Keep these
parts with the flange cover half for correct installa­ tion in their original positions.

CLEANING AND INSPECTION
(1) Clean all components (Fig. 4) in cleaning sol­
vent. Dry components with compressed air. (2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo­
nent in either pack is damaged. (3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged. (4) Inspect differential case and pinion shaft. Re­
place if worn or damaged.

ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both packs must be replaced. Lubricate each com­
ponent with gear lube before assembly and installa­ tion. (2) Clamp one axle shaft in a vise (with protective

jaws).
Tighten shaft in vise with the splined end ex­ tending approximately 76.2 mm (3.0 inches) upward (Fig. 5).
Fig.
5 Axle Shaft As
Holding
Fixture

(3) Saturate the clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into
the side gear plate in exactly the same position as re­ moved (Fig. 6).
(4) Line up the plate ears and install the assem­
bled pack into the flange half (Fig. 7). Make sure
Fig.
6
Clutch
Pack
Assembly

the clutch plate lugs enter the slots in the case.
Also make sure the clutch pack bottoms out on
the case.
Fig.
7
Clutch
Pack
Installation

(5) Install pinion mate shafts and pinion mate
gears (Fig. 8). Make sure shafts are correctly in­ stalled according to the alignment marks.
(6) Lubricate and install the other side gear and
clutch pack as done above in Step 3 (Fig. 8).