1998 DODGE RAM 1500 Workshop Manual

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Page 129 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader W-129-B with the Adapter
Plates 8142-A and install the safety holddown
clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread housing over 0.50 mm
(0.020 in). Failure to heed caution may result in
damage.
(4) Remove dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain in position on the
bearings and the differential preload shims are
seated in the housing. Tap differential case to ensure
bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader.
(8) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(9) Install axle shafts.
(10) Apply a bead of orange Mopar Axle RTV seal-
ant or equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied. Failure to heed caution may result in dam-
age.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N´m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings (3) from differential case (4)
with Puller C-293-PA (1) Adapters C-293-48 (2) and
Plug C-293-3 (5) (Fig. 42).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 43).
(2) Install differential into the housing.
Fig. 42 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 48 FRONT AXLE - C205FDR
DIFFERENTIAL (Continued)

Page 130 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from housing.
(2) Place differential

Page 131 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (17) Remove rear pinion bearing cup from housing
(Fig. 48) with Remover 8401 and Handle C-4171.
(18) Remove collapsible preload spacer (Fig. 49).
(19) Remove rear pinion bearing with Puller/Press
C-29

Page 132 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer

Page 133 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (7) Place pinion depth shim (Fig. 53) on the pinion
shaft.
(8) Install rear pinion bearing with Installer 6448
and a press (Fig. 54).(9) Installnewcollapsible spacer onto the pinion
shaft (Fig. 55).
(

Page 134 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (15) Invert differential case and start two ring
gear bolts to provide ring gear bolt hole alignment.
(16) Invert differential case in the vise.
(17) Installnewring gear bolts and alternately
tighten

Page 135 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page page
FRONT AXLE - 9 1/4 AA
DIAGNOSIS AND TESTING................54
REMOVAL.............................57
INSTALLATION.........................58
ADJUSTMEN

FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page page
FRONT AXLE - 9 1/4 AA
DIAGNOSIS AND TESTING................54
REMOVAL.............................57
INSTALLATION.........................58
ADJUSTMENTS........................59
SPECIFICATIONS.......................63
SPECIAL TOOLS.......................64
AXLE SHAFTS
REMOVAL.............................67
DISASSEMBLY.........................68
ASSEMBLY............................69
INSTALLATION.........................69
AXLE SHAFT SEALS
REMOVAL.............................69
INSTALLATION.........................70PINION SEAL
REMOVAL.............................70
INSTALLATION.........................71
DIFFERENTIAL
REMOVAL.............................72
DISASSEMBLY.........................72
ASSEMBLY............................73
INSTALLATION.........................74
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................75
INSTALLATION.........................75
PINION GEAR/RING GEAR
REMOVAL.............................75
INSTALLATION.........................77
FRONT AXLE - 9 1/4 AA
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. The side gears are loaded dur-
ing turns. They usually do not cause noise during
straight-ahead driving when the gears are unloaded.
A worn pinion mate shaft can also cause a snapping
or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint(s).
²Worn side-gear thrust washers.
²Worn pinion shaft bore.
3 - 54 FRONT AXLE - 9 1/4 AADR

Page 136 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual VIBRATION
Vibration at the front/rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out of balance wheels.
²Loose wheel lug nuts.
²Wo

VIBRATION
Vibration at the front/rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out of balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front end components
or engine/transmission mounts. These components
can contribute to what appears to be a vibration. Do
not overlook engine accessories, brackets and drive
belts.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged) can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear and lis-
ten for the noise. A mechanics stethoscope is helpful
in isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
DRFRONT AXLE - 9 1/4 AA 3 - 55
FRONT AXLE - 9 1/4 AA (Continued)

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