1993 DODGE TRUCK wheel bolts

3
- 14
REAR SUSPENSION
AND
AXLE
3
- 18
REAR SUSPENSION Fig.
6 Bearing
Removal
(9
1/4-Axle)

(4) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.

CAUTION:
Inspect
the
housing
bore for
burrs.
Re­
move
as
necessary.

BEARING
AND
SEAL
INSTALLATION
Always install a new seal. (1) Wipe the bore in the axle shaft tube clean.
(2) If the original bearing is not reusable, install a
new bearing.
• 8 3/8-Axle use Installer C-4198 with Handle
C-4171
• 9
1/4-Axle
use Installer C-4826 with Handle
C-4171

CAUTION:
DO NOT use the new axle
shaft
seal
to

position
or
seat
the bearing in the axle
shaft
bore.
(3) Insert the bearing into the tube. Ensure that
the bearing is not cocked and is seated firmly against
the tube shoulder.
(4) Install the new axle shaft seal (Fig. 7).
• 8 3/8-Axle use Installer C-4203 and Handle C-4171
• 9
1/4-Axle
use Installer C-4826 and Handle C-4171
SPECIAL
TOOL
SPECIAL
TOOL

Fig.
7 Axle Shaft
Seal
Installation
(5) When the tool cont

(face),
the seal will be a
depth.
AXLE SHAFT INSTALL* (1) Lubricate the bearin
the axle shaft and engage gear. Use care to prevei damaging the axle shaft
(2) Insert the C-clip loi
(Fig. 4). Push the axle s
C-clip lock.
(3) Insert the pinion ge
Install through the thrust
Align the hole in the shaf
Install the lock screw wit
Tighten the screw to 11 Is
3).

(4) Clean the cover anc
Refer to the Drain and Re
(5) Install the brake drv
(6) Install the wheel an
Tire Installation within th
cle.

(7) Raise or lower the
level.
(8) Remove the fill hole
housing with lubricant. I chart for the type and th
hole plug.
(9) Lower the vehicle. T
correct operation.

PINION
SEAL REPLACE!!

CAUTION:
The following

so
the correct pinion bea

tained.
If not completely f
failure
of the rear axle.
REMOVAL (1) Raise and support tr
(2) Mark the U-joint, pi]
for reference.
(3) Disconnect the drh
yoke. Secure the drive sha
prevent damage to the re*
(4) Remove the rear w
drums to prevent any dr
false bearing preload torq
(5) Use a Newton-mete
wrench to measure the p
tate the pinion shaft sev( wrench. Note the indicate moved through several re' (13) Install the brake drums.
(14) Install the wheels. Lower
(15) Adjust hoist so vehicle k
Check the differential housing h
essary, add sufficient amount.

COMPLETE AXLE REMOVAL/IN!
It is not necessary to remov
from the vehicle for routine or d
the differential housing or axle aged, the complete axle can 1
stalled.
REMOVAL (1) Raise the vehicle to a <
height that will permit support t at the front of the rear springs. (2) Block the brake pedal in tl
position with a wooden block. (3) Remove the rear wheels. '.
brake drum retaining clips oi
(4) Disconnect the brake flui
the wheel cylinders. Cap the fit of brake fluid.
(5) Remove the vent hose froi

pie.

(6) Remove the brake tee be
the brake fluid tubes from the c (7) Disconnect the parking bn
U-joint, pinion yoke, and pinion
Mark the U-joint, pinion yol
for reference. (8) Disconnect the drive she
yoke. Secure the drive shaft in a prevent damage to the rear U-jc
(9) Remove the shock absorl
nuts and bolts. Remove the reai
the U-bolts and the spring brad
(10) Remove the complete axL
(11) Wash and clean the outei
ing and tubes. Use an appropri; and dry the surface with comprc

INSTALLATION
(1) Position the rear axle sj
spring center bolts.
(2) Install the spring U-bolts
absorber lower bolts. Tighten tl
fled torque.
(3) Connect the parking brake
(4) Connect the brake fluid
wheel cylinders. Bleed and adjui (5) Align the installation refer
the drive shaft yoke to the pinii U-joint clamp bolts to 19-23 N
torque.
(6) Install the rear wheels. Ti|
correct tightening sequence.

REAR SUSPENSION
ANi
AXLE
3 - 17
(3) Eliminate any side play in the differential case.
Attach Dial Indicator to Pilot stud C-3288-B. Place
the indicator plunger at a right angle (90°) to the ring gear (Fig. 11). The plunger should exert a slight
force against the gear face.

DIAL

INDICATOR

Fig.
11
Ring
Gear
Runout
Measurement
(4) Measure the runout by turning the ring gear
several complete revolutions. Observe the dial indica­
tor pointer. Mark the ring gear and the differential
case at the areas of maximum runout. The ring gear
runout should not exceed 0.005 inch (0.13 mm). If the
runout exceeds 0.005 inch (0.13 mm), a damaged
dif­

ferential case could be the cause.
The marking on the differential case will be
very useful later during the differential case
runout. Remove the rear wheel anti-lock (RWAL) sensor.
(5) Mark the differential housing and the differen­
tial bearing caps for installation reference (Fig. 12).
(6) Remove the bearing threaded adjuster lock
from each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
(7) Loosen the threaded adjusters with Wrench
C-4164 (Fig. 13).
(8) Hold the differential case in place. Remove the
bearing caps (Fig. 14), adjusters and the differential
case.

Each differential bearing cup and threaded
adjuster must be kept with their respective bear­
ing.

PINION
GEAR
SHAFT
REMOVAL
(1) Remove the pinion gear nut and washer. Use
Puller C-452 and Wrench C-3281 to remove the pin­
ion gear yoke.
Fig.
12
Housing
&
Caps
Marked For
Installation

Reference
Fig.
13 Threaded Adjuster Tool

Fig.
14
Differential
Bearing Cap
Removed

(2) Use Puller C-748 to remove the pinion seal.
Discard the seal. (3) Force the pinion gear out the front bearing to

•

REAR
SUSPENSION
AND
AXLE
3-29
WARNING: WHEN SERVICING VEHICLES
WITH

SURE-GRIP,
DO NOT
USE THE ENGINE
TO
ROTATE
THE AXLE
AND
WHEELS. BOTH REAR WHEELS MUST BE RAISED AND
THE
VEHICLE SUPPORTED.

A
SURE-GRIP AXLE
CAN
EXERT ENOUGH FORCE
(IF ONE
WHEEL
IS IN
CONTACT
WITH
THE
SUR­ FACE)
TO
CAUSE
THE
VEHICLE
TO
MOVE.
LUBRICATION

Multi-Purpose Gear Lubricant, as defined by MIL-
L-2105-B (API GL-5) should be used in all axles.
MOPAR Hypoid Lubricant is recommended or equiv­ alent. In Sure-Grip differentials 4 ounces of MOPAR Hy­
poid Gear Lubricant Additive must be added with each re-fill.
It is recommended the vehicle be driven through 10
to 12 slow, figure-eight turns. This ensures the lubri­ cant is thoroughly pumped through the Sure-Grip
differential clutches.
MODEL 60 and 70 AXLES
INDEX

page

Axle Shaft Removal/Installation
32
Complete Axle Removal/Installation
........... 33
Differential
Assembly
38

Differential
Disassembly
34

Drain
and Refill 31

General
Information
29
Lubricant
31

GENERAL
INFORMATION

The housing (Fig. 1) consists of an iron center cast­
ing with axle shaft tubes extending from either side.
The tubes are pressed in to form a one-piece axle 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 axle
housing tubes. The full-float axle shafts are retained
by bolts attached to the hub. The hub rides on two
bearings at the outboard end of the axle tube. The axle shafts can be removed without disturbing or re­
moving the wheel bearings. The wheel bearings are
opposed tapered roller bearings that are part of the
hub/drum assembly.
page

Pinion Gear Depth Measurement
and
Adjustment
with Tool Set C-758-D6 43

Pinion Gear Depth Measurement
and
Adjustment
with

Tool
Set
D-116
. 40

Pinion Shaft Seal
31

Specifications
50

Wheel Bearing Service
33
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 and pinion teeth.
The differential case is a one-piece design. The
dif­

ferential pinion mate shaft is retained with a roll
pin. Model 70 axles with the optional Powr-Lok use a
two piece differential case. Differential bearing pre­ load and ring gear backlash are adjusted by the use
of shims located between the differential bearing
cones and case.

3
- 32
REAR
SUSPENSION
AND
AXLE

•
PINION SEAL

J9203-55

Fig.
4
Pinion
Seal
Removal

SPECIAL
TOOL
C-4735

J9203-56

Fig.
5
Pinion
Seal
Installation
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
the differential housing, if necessary. (6) Lower the vehicle.
DIFFERENTIAL

Fig.
6 Tightening
Pinion
Shaft Nut
AXLE
SHAFT
REiOWAL/INSTALLATlON

CAUTION:
RAISE
BOTH
REAR
WHEELS
off the
sur­

face whenever a rear axle is being
serviced.

REMOVAL-MODEL 60 (1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube (Fig.

1).

INSTALLATION-MODEL 60 (1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new flange gasket and slide the axle shaft into the tube (Fig. 1). (2) Install the bolts and tighten to 95 N»m (70 ft.
lbs.) torque.
REMOVAL-MODEL 70 (1) Remove the axle shaft flange lock nuts. (2) Strike the axle shaft sharply in the center of
the flange with a hammer to the loosen the tapered dowels. Slide the axle shaft out from the axle tube (Fig. 1).
INSTALLATION-MODEL 70 (1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube
(Fig. 1). (2) Install the tapered dowels and the lock nuts.
Tighten the lock nuts to 95 N*m (70 ft. lbs.) torque.

•

REAR
SUSPENSION
AND
AXLE
3 - 33
WHEEL BEARING SERVICE

REMOVAL (1) Remove the axle shaft, refer to the removal
procedure. (2) Remove the nut lock and adjustment nut.
(3) Remove the hub and drum assembly. The outer
wheel bearing will slide out as the hub is being re­
moved. (4) Place hub on bench and remove inner grease
seal. Discard seal. (5) Remove inner wheel bearing. Inspect wheel
bearings for wear. Replace as necessary.
CLEANING AND INSPECTION (1) Thoroughly clean both wheel bearings and in­
terior of the hub. Remove all of the residual lubri­ cant. (2) To clean the bearings:
• Soak them in an appropriate cleaning solvent
• Strike the flat of each bearing against a hardwood
block several times • Flush bearing between strikes
• Repeat the procedure above until each bearing is clean
• Dry the bearings with compressed air but do not
spin them (3) After cleaning, apply engine oil to each bear­
ing. (4) Rotate each bearing slowly while applying
downward force. Examine the rollers for pitting and
roughness. Replace worn or otherwise defective bear­
ings.
If a bearing has pitted and/or rough surfaced
rollers, replace both the bearing and bearing cup. (5) If reusable, remove the engine oil from each
bearing. Pack each bearing with multi-purpose
NLGI, grade 2, EP-type lubricant. Ensure that lubricant is forced into all the cav­
ities between the bearing cage and rollers.
INSTALLATION (1) If a bearing and cup must be replaced, remove
the cup from the hub bore. Use a brass drift or an appropriate removal tool to tap out the cup. (2) Install the replacement bearing cup(s) with an
appropriate installation tool.
(3) Apply lubricant to surface area of the hub bore.
Install the inner wheel bearing in the hub. Install a
replacement bearing seal with an appropriate seal installation tool. (4) Inspect the bearing and seal contact surfaces on
the axle for burrs and/or roughness.
(5) Remove all the rough contact surfaces from the

axle.
Apply a coating of multi-purpose NLGI, grade

2,
EP-type lubricant to the axle.

CAUTION:
Use care to prevent the inner
wheel
bear­
ing
and bearing
seal
from contacting the axle
threads
during installation. Otherwise, the
threads,

bearing,
and
seal
could
be
damaged.

(6) Carefully slide the hub onto the axle. Install
the outer wheel bearing, the locktab and outer wheel
bearing locknut.
(7) Tighten the adjustment nut to 163-190 Nnn
(120-140 ft. lbs.) torque while rotating the wheel. (8) Loosen the adjustment nut 1/3 of-a-turn (120
degrees) to provide 0.001-inch to 0.008-inch wheel
bearing end play.
(9) Tap the nut lock into the spindle keyway and
adjustment nut.
(10) Install the axle shaft, refer to the installation
procedure.

COMPLETE AXLE REMOVAL/INSTALLATION
REMOVAL It is not necessary to remove the complete axle
from the vehicle for routine or differential service. If
the differential housing or axle shaft tubes are dam­ aged, the complete axle can be removed and in­
stalled.
(1) Raise the rear of the vehicle until the rear
wheels are not contacting the surface. Support the
vehicle body at the front of the rear springs.
(2) Use a wooden block to retain the brake pedal
in the up position.
(3) Remove the axle shafts, wheels, hubs and
brake drums. If necessary, refer to the applicable re­ moval procedures.
(4) Disconnect the brake line and cap the fittings
to prevent loss of brake fluid. (5) Disconnect the parking brake cables.
Scribe installation alignment reference marks
on drive shaft U-joint and on pinion yoke. (6) Disconnect the drive shaft U-joint from the pin­
ion yoke. Secure it in an upright position to prevent
damage to the U-joint.
(7) Remove the rear shock absorbers and the rear
spring U-bolts from the axle. (8) Remove the rear axle from the vehicle.
INSTALLATION (1) If the differential housing cover was removed,
ensure differential housing and cover mating sur­
faces are clean.
(2) If cover was removed, apply a bead of MOPAR
Silicone Rubber Sealant around the cover bolt circle.
Install the differential housing cover. Tighten the
cover bolts to 47 N»m (35 ft. lbs.) torque. Install the axle gear ratio identification tag under one of
the cover bolts.
(3) With the vehicle body supported at the front of
the rear springs, position the axle under the rear springs.

3
- 34
REAR SUSPENSION
AND
AXLE

• (4) Install the spring U-bolts and tighten the nuts
with the specified torque.
(5) Install the shock absorbers.
(6) Connect the parking brake cables.
(7) Connect the brake lines. Install the hubs and
brake drums. Adjust the wheel bearings (refer to Wheel Bearing Adjustment).
(8) Remove the block from the brake pedal. Bleed
and adjust the brakes.
(9) Connect the drive shaft to the pinion yoke with
the reference marks aligned. Tighten the U-joint clamp bolts to 21 N-m (16 ft. lbs./186 in. lbs.) torque.
(10) Install the rear wheels and tighten the lug
nuts with the specified torque (refer to Group 22,
Wheels And Tires). (11) Raise the rear of the vehicle, remove the sup­

ports,
level the vehicle and position the supports. (12) Remove the fill hole plug from the differential
housing cover. Fill the differential housing to the correct level with MOPAR Hypoid Gear Lubricant, or
an equivalent product. Add 4 ounces of MOPAR Hypoid Gear Lubri­
cant Additive for Trac-Lok equipped axles. (13) Install the fill hole plug. Remove the supports
and lower the vehicle. (14) Road test the vehicle to evaluate the results of
the repair.

DIFFERENTIAL
DISASSEMBLY
RE MO VA
L/DISA
SSEMBL Y
Remove the RWAL brake sensor
hold-down

bolt and pull the sensor from the differential
housing. The sensor must be removed to prevent damage when disassembling or assembling the differential components.
(1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 7). (2) Remove the differential bearing caps.
Fig.
7 Bearing Cap
identification
(3) Position Spreader D-167 with the tool dowel
pins seated in the locating holes (Fig. 8). Install the holddown clamps and tighten the tool turnbuckle fin­
ger-tight.

SPECIAL TOOL DIAL

MODEL
44-W-129-A
INDICATOR

Fig.
8
Differential
Housing
Separation
(4) Install a pilot stud at the left side of the differ­
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 8) and zero the indicator.

CAUTION:
Do not
spread
over the specified
dis­

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

(5) Separate the housing enough to remove the
case from the housing. Separate housing a maxi­
mum distance of 0.38 mm (0.015 in) with the spreader tool. Measure the distance with the dial
indicator (Fig. 8).
(6) Remove the dial indicator. (7) Pry the differential case loose from the hous­
ing. To prevent damage, pivot on housing with the
end of the pry bar against case.
(8) Remove the case from housing. If they are re­
usable, retain the differential bearing cups and bear­ ings together as matched sets.
(9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear

bolts.
Tap the ring gear with a rawhide mallet and
remove (Fig. 9).
(10) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 10).
(11) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).
(12) Remove oil slinger, front bearing and shims
(Fig. 11). Record the thickness of the shims. This will
save time if they should become misplaced.
(13) The excitor ring can be removed with a soft-
faced hammer (Fig. 12). Discard after removal.

•

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