1993 DODGE TRUCK Service Repair Manual

2
- 12
FRONT
SUSPENSION
AND
AXLE

•
1—Nut

2—Lockwasher

3—Cam
4—Bushing

5—Ball Joint
6—Locknut
7—Upper
Suspension
Arm
8—Upper Ball Joint Seal

9—Bumper
10—Sleeve

11—Cam
and Bolt
J9202-98

SP-3952A
Fig.
9 Upper
Suspension
Arm Removal/Installation

INSTALLATION
(1) Thread the replacement ball stud into the up­
per suspension arm bore as far as possible by hand.
Use Wrench C-3561 to tighten the ball stud to 169
N«m (125 ft. lbs.) torque. Ensure that the ball stud
is completely seated against the arm.
(2) Install and seat the replacement ball stud seal.
(3) Insert the upper ball stud into steering
knuckle. Install ball stud nuts. Tighten the nuts to 142 N#m (105 ft. lbs.) torque. Install replacement cot­
ter pins.
(4) Install the wheel/tire. Remove the support and
lower the vehicle to the surface.
BUSHING

SP-3953

RH393
UPPER
SUSPENSION
ARM BUSHING

REPLACEMENT

REMOVAL

(1) Follow procedure under Upper Suspension Arm
Removal.
(2) Place the upper suspension arm in a vise. As­
semble Remover/Installer C-3962 and Adaptor
SP-3953 (Fig. 10) over the bushing. Tighten the nuts and force the bushing out of the arm bore.

INSTALLATION
Be sure the suspension arm is supported
firmly at the area where the bushing is being
Fig.
10 Upper
Suspension
Arm
Bushing
Removal

forced in the bore. Do not use oil or any other
lubricant to aid the installation. (1) Position flange end of the replacement bushing
in Remover/Installer C-3962. Support suspension arm
firmly and force the bushing in the suspension arm
bore (from outside). Tighten until the flanged end is seated on the arm (Fig. 11).
(2) Follow procedure under Upper Suspension Arm
Installation.

•

Fig.
11 Upper Suspension Arm Bushing installation

STEERING KNUCKLE
REMOVAL
(1) Block the brake pedal in the up position. Raise
the vehicle and remove the wheel cover and wheel/
tire.
Remove the brake caliper, refer to Group 5,
Brakes. (2) Remove the brake rotor from the spindle. Refer
to Wheel Hub and Bearings service procedures
within this Group.
(3) Remove the brake splash shield. Remove and
discard the dust seal.
(4) Remove the cotter pin and the nut from the tie-
rod end ball stud.

(5)
Install Puller Tool C-3894A (Fig. 12) and apply
sufficient force with the tool to loosen the tie-rod end
ball stud from the steering knuckle arm bore.
Fig.
12 Tie-Rod End
Ball
Stud
Removal
FRONT SUSPENSION
AND
AXLE
2 - 13

Fig.
13 Steering
Knuckle

(16) Remove the brake adapter and steering
knuckle bolts from the steering knuckle. Separate
the components.
INSTALLATION (1) Install the brake adaptor on the steering
knuckle. Tighten the bolts to 136 Nnn (100 ft-lbs)
torque.
(2) Align the steering knuckle arm bolt holes with
the steering knuckle bolt holes. Install the bolts and
tighten to 291 Nnn (215 ft-lbs) torque. (6) Remove the shock absorber from the vehicle,
refer to the removal procedures. (7) Install Spring Compressor Tool DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(8) Remove the cotter pins and the lower and up­
per ball stud nuts at the steering knuckle.
(9) Install Ball Stud Loosening Tool C-3564-A on
the lower ball stud (Fig. 4). Turn the threaded por­
tion of the tool and lock the tool securely against the lower stud (Fig. 5). Expand the tool enough to place
force on the lower ball stud. Strike the steering
knuckle sharply with a hammer to loosen the stud.
Do not attempt to force the stud out of the steer­
ing knuckle with the loosening tool.
(10) Remove the loosening tool and remove the
lower ball stud from the steering knuckle bore with an appropriate tool.
(11) Reverse the position of Ball Stud Loosening
Tool C-3564-A, and remove the upper ball stud.
(12) Remove the loosening tool.
(13) Remove the upper ball stud from the steering
knuckle bore with an appropriate tool. (14) Slowly loosen the coil spring compressor tool
(Fig. 5) until all tension is relieved from the spring.
(15) Separate the steering knuckle and the steer­
ing knuckle arm from the ball studs (Fig. 13).

2
- 14
FRONT SUSPENSION
AND
AXLE

• (3) Mount the knuckle to the suspension arms and
install the nuts. Tighten the upper nut to 142 Nnn (105 ft-lbs) torque and the lower nut.
• 11/16-16 bolt, to 183 Nnn (135 ft-lbs) torque
• 3/4-16 bolt, to 237 Nnn (175 ft-lbs) torque Install replacement cotter pins. (4) Connect the tie-rod end. Install and tighten the
nut to 61 Nnn (45 ft-lbs) torque. Install a replace­
ment cotter pin. (5) Position a replacement dust seal on the steer­
ing knuckle. Install the splash shield and tighten the
bolts to 24 Nnn (18 ft. lbs.) torque. (6) Install the shock absorber, refer to the installa­
tion procedures.
(7) Install the hub/rotor, refer to the procedures
above.
(8) Install the brake caliper, refer to Group 5,
Brakes for additional installation information.

(9)
Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.
(10) Test the vehicle brakes and the front suspen­
sion for proper operation.

FRONT
SUSPENSION—4WD VEHICLES

STABILIZER
BAR REMOVAL
(1) Remove the link rod nut at each end of the sta­
bilizer bar (Fig. 1).
STABILIZER BAR

FRONT

STABILIZER BAR BUSHING
RETAINER

LINK
ROD

J9017-37

Fig.
1
Stabilizer
Bar (2) Remove the outer retainers and rubber bush­
ings from the link rods (Fig. 1). (3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer
bar from the vehicle (Fig. 1).
INSTALLATION (1) Position the stabilizer bar ends over the link

rods.
Install the U-shaped support brackets and bolts/
nuts (Fig. 1). Tighten the bolts/nuts to 23 Nnn (200
in. lbs.) torque.
(2) Install the outer retainers and rubber bushings
on the link rods (Fig. 1). (3) Install the link rod nuts (Fig. 1). Tighten the
nuts to 11 Nnn (100 in. lbs.).
SHOCK
ABSORBER

SERVICE INFORM
A TION Air-adjustable shock absorbers are installed on ve­
hicles equipped with the Heavy Duty Snow Plow Package and Diesel engine.

REMOVAL
(1) Remove the shock absorber upper nut and re­
tainer from the frame bracket (Fig. 2).
PLATE
BRACKET
NUT
AXLE NUT
AXLE

J9202-99

Fig.
2
Shock
Absorber
(4
WD)
(2) Remove the shock absorber lower nut and re­
tainer from the axle. Pull the shock outward at top and swing down to remove.
(3) Remove the inner retainers from the mounting

studs.

INSTALLATION (1) Before installing the shock absorber, ensure
that the bushing is inserted in the shock absorber
eye.

•

FRONT
SUSPENSION
AND
AXLE
2 - 15 Ensure the shock absorber is positioned on the
stud with retainers correctly located (Fig. 2).
(2)
Position the inner retainers on the mounting

studs.

(3) Install the shock on the upper and lower stud
and install the outer retainers.
(4) Install the nuts on the frame bracket and axle
(Fig. 2). (5) Tighten the shock absorber upper and lower

nuts;
• Standard shock upper and lower nut to 75 Nnn (55
ft. lbs.) torque
• Air-adjustable shock upper nut to 75 N»m (55 ft. lbs.) torque, lower nut to 271 Nnn (200 ft. lbs.)
torque

CAUTION:
Vehicles
with
air
shocks MUST
maintain

a
minimum
pressure
of 10 to 15 psi (70 to 105 kPa). Operation below the specified minimum
pressures
may cause damage.

(6) Remove the supports and lower the vehicle.

LEAF
SPRINGS
REMOVAL
(1) Raise and support the frame until all weight is
removed from the front springs. (2) With the front tires in contact with the surface,
position support stands under the frame side rails. (3) Remove the nuts, lockwashers, U-bolts that at­
tach the spring to the axle shaft tubes (Fig. 3).
SPRING
BRACKET SPRING
BRACKET SPRING
SHACKLE
PLATE
FRONT
SPRING
AXLE
TUBE U-BOLT LEFT
SIDE

J9017-33

Fig.
3 Front
Suspension
(4) Remove the spring front eye pivot nut and bolt,
rear spring shackle nuts, shackle plates. Remove the spring from the vehicle (Fig. 3).
INSTALLATION

(1) Align the spring front eye with the bolt hole in
the frame bracket and install the pivot bolt and nut (Fig. 3). (2) Position the shackle plates at the spring rear
eye and frame rail bracket. Install the nuts (Fig. 3). (3) Tighten the shackle plate nuts and front pivot
bolt nut until all slack is taken up. (4) Position the spring on the axle tube with the
spring center bolt seated in locating hole in axle tube
pad (Fig. 3).
(5) Install the U-bolts, new lockwashers and nuts.
(6) Tighten the nuts snug against the spring
bracket.
(7) Remove the supports and lower the vehicle
with the weight being supported by the tires. (8) Tighten the spring nuts according to the follow­
ing specifications:
• Model 44 Axle: U-bolt/Stud nuts - 115 Nnn (85 ft. lbs.) torque
Front pivot bolt/nut — 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut — 81 Nnn (60 ft. lbs.) torque
• Model 60 Axle: U-bolt nuts - 129 Nnn (95 ft. lbs.) torque Front pivot bolt/nut - 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut - 108 Nnn (80 ft. lbs.)
torque

SPRING LEAF-REPLACEMENT
If a spring has acquired a set (lost significant
height), it should be replaced. (1) Remove the spring from the vehicle. If neces­
sary, refer to the removal procedure. (2) Remove the spring leaf alignment clips.
(3) Clamp the spring in a vise. Remove the nut
and center bolt (Fig. 4).
SPRING

CENTER
RATCHET
AND

SOCKET

WRENCH

Fig.
4 Leaf
Spring
Disassembly
(4) Insert a long drift or punch into the center bolt
hole and slowly release the vise jaws.

2-16
FRONT
SUSPENSION
AND
AXLE

• (5) Remove the spring from the vise. Replace the
broken/defective
leaf.
Insert a long drift or punch into the spring center bolt hole.
(6) Position the spring between vise jaws and
slowly tighten the vise jaws. Keep the spring leaves
aligned with the long drift or punch.
(7) Remove the drift/punch from the spring center
bolt hole. Install a replacement center bolt and nut (Fig. 4).
(8) Tighten the nut to 27 N*m (20 ft. lbs.) torque.
An alternate is to tighten until the center of the spring has no gaps. Use a maximum of 54 N*m (40 ft.
lbs.) torque for this method.
(9) Install the alignment clips.
(10) Install the spring in the vehicle. If necessary
refer to the installation procedure.

LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 5). Tighten the nut
located at the socket wrench end of the threaded rod
until the bushing is forced out. (2) Assemble and align the bushing installation

tools.
(3) Align the bushing with the spring eye and
tighten the nut located at the socket wrench end of
the threaded rod. Tighten until the bushing is forced into the spring eye. The bushing must be centered in the spring
NUT
PIPE
(RECEIVER)
SPRING
EYE

SOCKET
WRENCH
(DRIVER)
NUT

FLAT

WASHER THREADED
ROD
J8917-20

Fig.
5
Spring
Eye
Bushing
Removal

eye.
The ends of the bushing must be flush or slightly recessed within the end surfaces of the
spring eye.

•

FRONT
SUSPENSION
AND
AXLE
2 - 17
MODEL
44
FRONT
AXLE

INDEX

page

Axle Shaft
and
U-Joint
Service
23
Complete Axle Removal/Installation
31

Differential
Assembly
35

Differential
Disassembly
. 32

Drain
and Refill
19

General
Information
17
Hub,
Spindle
and
Axle Shaft
20
Intermediate
Axle Shaft
30

Lubricant
17

GENERAL
INFORMATION

Model
44
front axles
(Fig. 1)
consists
of an
iron
center casting with axle shaft tubes extending from
either side. The integral type housing, hypoid gear design
has

the centerline
of the
pinion
set
below
the
centerline of
the
ring gear. The axle shaft disconnect housing
is
welded
to the

left axle shaft tube.
A
splined, two-piece axle shaft
is

located
on the
left side
and it is
engaged
or
disen­
gaged
by a
shift collar.
The
collar
is
moved
by a
shift
fork controlled
by a
vacuum shift motor.
The
shift motor
is
operated
by
engine vacuum controlled
by a
switch located
at the
transfer case. The axles
are
equipped with full-floating axle

shafts,
meaning that loads
are
supported
by the
spin­
dles attached
to the
steering knuckles. The removable, stamped steel cover provides
a

means
for
inspection
and
service without removing
the complete axle from
the
vehicle.
page

Pinion Gear Depth Measurement
and
Adjustment
with
Tool
Set
C-3715-B
40

Pinion Gear Depth Measurement
and
Adjustment
with
Tool
Set
D-115-44
... 38

Pinion Shaft Seal
19

Specifications
48

Steering Knuckle
Arm
31

Steering Knuckle, Upper
and
Lower Ball Studs
. . 24

Vacuum
Shift Motor
26

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 gear
and
pinion gear teeth.
The differential case
is a
one-piece design.
The dif­

ferential pinion mate shaft
is
retained with
a
roll
pin. Differential bearing preload
and
ring gear back­ lash
are
adjusted
by the use of
shims located between
the differential bearing cones
and
case.

LUBRICANT
Multi-purpose
API GL 5
quality hypoid gear lubri­
cant should
be
used
for
Model
44
axles. MOPAR
Hy­

poid Gear Lubricant conforms with these specifications
and is
recommended.

CAUTION:
If a
front axle
is
submerged
in
water,
the

axle lubricant must
be
replaced immediately.

J9202-105

Fig. 1 Model 44 Front Axle

FRONT
SUSPENSION
AND
AXLE
2 - 19

DRAIN
AND
REFILL

(1) Drive the vehicle until the gear lubricant
reaches normal operating temperature. (2) Raise and support the vehicle.
(3) Remove the lubricant fill hole plug from the
differential housing cover.
(4) Remove the differential housing cover. Allow
the original lubricant to completely drain from the
housing and axle shaft tubes.
(5) With standard differential, clean the differen­
tial and the housing cavity with a flushing oil (or light engine oil). This will remove the residual lubri­cant and foreign matter. Do not use water, steam,
kerosene or gasoline for flushing. (6) Scrape the residual gasket from the housing
and cover mating surfaces. Clean the mating sur­
faces with mineral spirits. Install a new cover gas­ ket. Apply a bead of MOPAR® Silicone Rubber Sealant on the housing cover (Fig. 2). Allow the
sealant to cure for a few minutes.

SEALING

SURFACE
CONTOUR
OF
BEAD
BEAD

THICKNESS

6.35mm
(1/4")
J9302-30

Fig.
2 Sealant On
Housing
Cover

Install the housing cover within 5 minutes af­
ter applying the sealant. If not installed the seal­ ant must be removed and another bead applied.
(7) Install the cover on the differential with the

bolts.
Install the identification tag. Tighten the cover
bolts to 47 Nnn (35 ft. lbs.) torque.

CAUTION:
Overfilling the
differential
can result in
the lubricant
foaming
and overheating.
(8) Refill the differential housing with the speci­
fied quantity of MOPAR® Hypoid Gear Lubricant.
(9) Install the fill hole plug and tighten to 34 N#m
(25 ft. lbs.) torque.
(10) Road test the vehicle.
PINION
SHAFT
SEAL

REMOVAL
(1) Raise and support the vehicle.
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to prevent damage to the rear U-joint.
(4) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 3).
(5) Mark the positions of the yoke and pinion gear
for installation alignment reference.

SPECIAL
TOOL
C-3281

SPECIAL
TOOL
C-452
J9102-31

Fig.
3
Pinion
Yoke
Removal

(6) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).
PINION
SEAL

SPECIAL
TOOL
C-748

Fig.
4
Pinion
Seal
Removal
J9203-55