1998 DODGE RAM 1500 Front axle

Condition Possible Causes Correction
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion
depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he
proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position a lifting device under axle and secure
lift to the axle.
(3) Remove wheels and tires assemblies.
(4) Remove all brake components.
(5) Mark propeller shaft and companion flange for
installation alignment reference.
(6) Remove propeller shaft.
(7) Remove shock absorbers from axle (Fig. 1).
(8) Remove U-bolts from axle (Fig. 2).(9) Remove axle from the vehicle.
Fig. 1 SHOCK ABSORBER
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 2 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
4 - FRONT NUT & BOLT
5 - SPRING CLAMP BOLTS
6 - SHACKLES
DRREAR AXLE - 11 1/2 AA 3 - 143
REAR AXLE - 11 1/2 AA (Continued)

INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.
(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install all brake components.
(5) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(6) Install the wheels and tires.
(7) Fill differential to specifications.
(8) Remove lift from axle and lower the vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets. Compensation for pinion depth variance is
achieved with a select shim, located between the rear
pinion bearing and pinion gear head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 3).(1) Assemble Pinion Height Block 6739, Pinion
Block 8897 and rear pinion bearing onto Screw 6741
(Fig. 3).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 4).
(3) Install front pinion bearing and Cone-nut 6740
onto the screw. Tighten cone-nut until Torque To
Rotate the screw is 1.7-2.26 N´m (15-20 in. lbs.) (Fig.
3).
(4) Place Arbor Discs 8289 on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 5).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 281 N´m (207 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 6). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
Fig. 3 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 4 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 144 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11 1/2 AA (Continued)

(4) Remove hub bearing nut with Socket 8954.
(5) Remove hub and bearings from the axle.
(6) Pry out hub bearing seal from the back of the
hub.
NOTE: The inner part of the seal may stay on the
axle tube (Fig. 20). This part must also be removed.
(7) Remove rear bearing.
(8) Remove hub bearing cups with a hammer and
drift.
INSTALLATION
(1) Install outer hub bearing cup with Installer
8961 and Handle C-4171.
(2) Install inner hub bearing cup with Installer
8153 and Handle C-4171.
(3) Pack bearings with the appropriate wheel bear-
ing grease.
(4) Install rear bearing and installnewgrease
seal with Installer 8963 and Handle C-4171.
(5) Slide hub on the axle tube and install front
bearing into the hub.
(6) Install hub bearing nut with Socket 8954 and
tighten to 30 N´m (22 ft. lbs.) while rotating the hub
(Fig. 21).
(7) Back off nut about 30É and align next hub nut
key slot with axle tube key slot and install locking
key.
NOTE: End play should be 0.025-0.25 mm
(0.01-0.001 in.)
(8) Install retainer ring with ring end in the key
slot.
(9) Install new axle shaft gasket and install the
axle shaft.
PINION SEAL
REMOVAL
(1) Remove axle shafts.
(2) Mark the propeller shaft and pinion flange for
installation reference.
(3) Remove propeller shaft.
(4) Rotate pinion gear three or four times.
(5) Measure and record the amount of torque nec-
essary to rotate the pinion gear with an inch pound
torque wrench (Fig. 22).
(6) Hold pinion flange with Flange Wrench 8979
(Fig. 23) and remove pinion flange nut.Fig. 20 INNER PART OF SEAL
1-PRYBAR
2 - AXLE TUBE
3 - REMAINING SEAL
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
Fig. 22 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
DRREAR AXLE - 11 1/2 AA 3 - 153
AXLE BEARINGS (Continued)

(10) Remove pinion gear from housing with Pinion
Driver 8977 and a hammer (Fig. 53).
NOTE: Thread the driver on the pinion shaft till it
bottoms out.
(11) Remove pinion seal with a slide hammer or
pry bar.(12) Remove front pinion bearing and discard bear-
ing.
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove collapsible spacer from the pinion
shaft.
Fig. 50 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 51 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
Fig. 52 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 53 PINION DRIVER
1 - PINION SHAFT
2 - PINION DRIVER
DRREAR AXLE - 11 1/2 AA 3 - 163
PINION GEAR/RING GEAR/TONE RING (Continued)

(14) Remove rear pinion bearing with Bearing
Splitter 1130 and a press (Fig. 54).
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the
housing with a punch and hammer, and discard cup.
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the
housing with a punch and hammer, if bearing is
going to be replaced.
INSTALLATION
(1) Install new front pinion bearing cup (Fig. 55)
with Installer 8960 and Handle C-4171.(2) Install new rear pinion bearing cup (Fig. 56)
with Installer 8968 and Handle C-4171.
(3) Install pinion depth shim (Fig. 57) on the pin-
ion gear shaft.
Fig. 54 BEARING SPLITTER
1 - PINION BEARING
2 - SPLITTER
Fig. 55 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 56 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 57 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
3 - 164 REAR AXLE - 11 1/2 AADR
PINION GEAR/RING GEAR/TONE RING (Continued)

(4) Install rear pinion bearing (Fig. 58) with
Installer D-389 and a press.
(5) Installnewcollapsible spacer (Fig. 59).
(6) Lubricate pinion and bearings.
(7) Install pinion into the housing and place front
pinion bearing onto the pinion shaft. Draw the pinionshaft into the front bearing with Installer 8981 (Fig.
60).
(8) Installnewpinion seal (Fig. 61) with Installer
8896 and Handle C-4171.
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange
onto the pinion, until a few threads are showing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
(Fig. 62) and tighten pinion nut until pinion end play
is taken up.
(13) Rotate pinion several times to seat bearings.
(14) Measure pinion rotating torque with an inch
pound torque wrench (Fig. 63). Tighten pinion nut in
small increments until pinion rotating torque is:
²New Pinion Bearings:1.7-2.8 N´m (15-25 in.
lbs.)
²Original Pinion Bearings:1.1-2.2 N´m (10-20
in. lbs.)
Fig. 58 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 59 COLLAPSIBLE SPACER
1 - COLAPSIBLE SPACER
2 - PINION GEAR
3 - REAR PINION BEARING
Fig. 60 PINION GEAR INSTALLER
1 - INSTALLER
2 - DIFFERENTIAL HOUSING
Fig. 61 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
DRREAR AXLE - 11 1/2 AA 3 - 165
PINION GEAR/RING GEAR/TONE RING (Continued)

(7) Remove the mounting bolt for the brake hose
at the axle (Fig. 8).
(8) Remove the hose.
REMOVAL - REAR TUBE / HOSE ASSEMBLY
(1) Install prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support the vehicle.
(3) Remove the brake line located at the axle.
(4) Remove the mounting bolt for the brake hose
at the axle (Fig. 9).
(5) Remove the banjo bolt at the caliper (Fig. 9).
(6) Remove the hose.
REMOVAL - FRONT HOSE
(1) Install a prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove the tire and wheel assembly.
(4) Remove the brake hose from the brake line
located at the frame (Fig. 10).
(5) Remove the brake hose banjo bolt at the caliper
(Fig. 10).
(6) Remove the mounting bolt securing the brake
hose to the frame and remove the wheel speed sensor
wire from the brake hose (Fig. 10).
(7) Remove the hose.
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 8).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 8).
(4) Install the vent tube (Fig. 8).
(5) Install the brake hose clip at the top of the
hose located at the frame (Fig. 7).
(6) Install the brake line to the hose at the frame
(Fig. 7).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
Fig. 8 REAR HOSE
1 - BRAKE HOSE
2 - VENT HOSE
3 - BRAKE LINES
Fig. 9 BRAKE LINE WITH RUBBER HOSE
1 - BANJO BOLT
2 - MOUNTING BOLT
3 - REAR TUBE / HOSE ASSEMBLY
Fig. 10 BRAKE HOSE MOUNTED PASSENGER SIDE
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BANJO BOLT
4 - WHEEL SPEED SENSOR WIRE
5 - 12 BRAKES - BASEDR
BRAKE LINES (Continued)

INSTALLATION - REAR TUBE / HOSE
ASSEMBLY
(1) Install the hose.
(2) Install the banjo bolt at the caliper (Fig. 9) and
tighten fitting bolt to 27 N´m (245 in. lbs.).
(3) Install the mounting bolt for the brake hose at
the axle (Fig. 9).
(4) Install the brake line located at the axle.
(5) Lower the vehicle and remove the support.
(6) Remove the prop rod.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the frame (Fig. 11).
(3) Install the brake hose banjo bolt at the caliper
(Fig. 10).
(4) Reinstall the wheel speed sensor wire to the
brake hose (Fig. 10).
(5) Remove the support and lower the vehicle.
(6) Remove the prop rod from the brake pedal.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT
(1) Raise and support vehicle.
(2) Remove the wheel and tire assemblies.(3) Compress the caliper.
(4) Remove the caliper, (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL).
(5) Remove the caliper by tilting the top up and off
the caliper adapter (Fig. 12).
NOTE: Do not allow brake hose to support caliper
assembly.
(6) Support and hang the caliper. (Fig. 13)
(7) Remove the inboard brake shoe from the cali-
per adapter (Fig. 14).
Fig. 11 BRAKE HOSE MOUNT DRIVERS SIDE
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR WIRE
3 - BRAKE HOSE
Fig. 12 Caliper
1 - CALIPER
2 - CALIPER ADAPTER
Fig. 13 DISC BRAKE CALIPER - FRONT
1 - STEERING KNUCKLE
2 - DISC BRAKE CALIPER
3 - CALIPER MOUNTING ADAPTER
4 - DISC BRAKE ROTOR
DRBRAKES - BASE 5 - 13
BRAKE LINES (Continued)