1998 DODGE RAM 1500 fig

DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 7).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zerobacklash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 (Fig. 8) until they make contact with the differ-
ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
Fig. 5 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 6 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 7 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 8 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
DRREAR AXLE - 10 1/2 AA 3 - 117
REAR AXLE - 10 1/2 AA (Continued)

(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.
(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 9).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern correct (Fig. 10). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
11). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 10 CORRECT CONTACT PATTERN
Fig. 11 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 118 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

²Ring gear too far away from pinion gear (Fig.
13). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 14).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
²Pinion gear is set too low (Fig. 15). Increase the
pinion gear height, by increasing the pinion depth
shim thickness.
²Pinion gear is set too high (Fig. 16). Decrease
the pinion depth, by decreasing the pinion depth
shim thickness.
Fig. 12 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
Fig. 13 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 14 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 15 LOW PINION HEIGHT
Fig. 16 HIGH PINION HEIGHT
DRREAR AXLE - 10 1/2 AA 3 - 119
REAR AXLE - 10 1/2 AA (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove axle shaft flange bolts (Fig. 17).
(2) Slide axle shaft out of the axle tube.
(3) Remove axle shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use
Mopar Lock N' Seal or LoctiteT242 on cleaned
existing bolts.
(1) Clean axle flange and hub.
(2) Install new axle shaft gasket.
(3) Slide axle shaft into the axle tube.
(4) Install axle shaft flange bolts and tighten to
129 N´m ( 95 ft. lbs.).
PINION INSTALLER 8981
FLANGE PULLER 8992
BRIDGE 938
Fig. 17 AXLE FLANGE BOLTS
1 - AXLE FLANGE
2 - FLANGE BOLT
3 - 124 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

AXLE BEARINGS
REMOVAL
(1) Remove axle shaft flange bolts and remove axle
shaft.
(2) Remove retianer ring (Fig. 18) from the axle
shaft tube.
(3) Remove hub bearing nut locking key (Fig. 19).(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
8962 and Handle C-4171.
(3) Pack bearings with the appropriate 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
(0.001-0.010 in.).
Fig. 18 RETAINER RING
1 - RETAINER RING
2 - LOCKING KEY
3 - BEARING NUT
Fig. 19 LOCKING KEY
1 - BEARING NUT
2 - LOCKING KEY
3 - AXLE TUBE
Fig. 20 INNER PART OF SEAL
1-PRYBAR
2 - AXLE TUBE
3 - REMAINING SEAL
DRREAR AXLE - 10 1/2 AA 3 - 125

(8)Install retainer ring with ring end in the key slot.
(9) Install new axle shaft gasket and install axle
shaft.
PINION SEAL
REMOVAL
(1) Remove axle shafts.
(2) Mark propeller shaft and pinion flange for
installation reference and remove shaft.
(3) Rotate pinion gear three or four times.
(4) Measure and record the amount of torque nec-
essary to rotate the pinion gear with an inch pound
torque wrench (Fig. 22).(5) Hold pinion flange with Flange Wrench 8979
(Fig. 23) and remove pinion flange nut and washer.
(6) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 24).
(7) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8896 and
Handle C-4171 (Fig. 25).
(2) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
Fig. 22 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 23 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
Fig. 24 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
3 - 126 REAR AXLE - 10 1/2 AADR
AXLE BEARINGS (Continued)

(5) Hold flange with Flange Wrench 8979 (Fig. 26)
and tighten pinion nut until pinion end play is taken
up.
(6) Rotate pinion several times to seat bearings.
(7) Measure pinion rotating torque with an inch
pound torque wrench and compare it to recorded
measurement.
(8) Tighten pinion nut in small increments, until
pinion rotating torque is 0.40-0.57 N´m (3-5 in. lbs.)
greater than recorded measurement.
(9) Rotate pinion several times then verify pinion
rotating torque again.
(10) Install axle shafts.
(11) Install propeller shaft with reference marks
aligned.
(12) Check and fill differential if necessary.
DIFFERENTIAL
REMOVAL
(1) Remove lubricant fill hole plug from the differ-
ential housing cover.
(2) Remove differential housing cover and drain
the lubricant from housing.
(3) Remove axle shafts.
(4) Remove adjuster lock bolts and adjuster locks
(Fig. 27).
(5) Mark bearing caps left and right for installa-
tion reference.
(6) Remove bearing cap bolts and remove bearing
caps.
(7) Loosen differential bearing adjusters (Fig. 28)
with Spanner Wrench 8883.
(8) Remove differential case from the housing.
(9) Remove bearing cups and tag them left and
right for installation reference.
Fig. 25 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 26 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 27 ADJUSTER LOCKS
1 - LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
DRREAR AXLE - 10 1/2 AA 3 - 127
PINION SEAL (Continued)

DISASSEMBLY
(1) Remove pinion shaft with a hammer and punch
from the side with the hole in the pinion shaft (Fig.
29).
(2) Rotate one pinion gear with thrust washer
(Fig. 30) to the differential window and remove the
gear.(3) Rotate the other pinion gear with thrust
washer (Fig. 31) to the differential window and
remove the gear.
(4) Remove differential side gears and thrust
washers (Fig. 32).
Fig. 28 BEARING ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
Fig. 29 PINION SHAFT
1 - PINION GEAR
2 - PINION SHAFT
3 - RING GEAR
4 - EXCITER RING
Fig. 30 FRIST PINION GEAR
1 - DIFFERNTIAL CASE WINDOW
2 - PINION GEAR
3 - THRUST WASHER
Fig. 31 SECOND PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - THRUST WASHER
3 - PINION GEAR
3 - 128 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)