1998 DODGE RAM 1500 ECU

(7) Apply the grease supplied with the joint/boot to
the ball races. Spread the grease equally between all
the races.
(8) Tilt inner race/hub and cage and install the
balls (Fig. 13).
(9) Place new clamps onto new boot and slide boot
onto the shaft to it's original position.
(10) Apply the rest of grease to the C/V joint and
boot.
(11) Install the joint onto the shaft. Push the joint
onto the shaft until the snap ring seats in the groove
(Fig. 14).NOTE: Pull on the joint to verify the span ring has
engaged.
(12) Position the boot on the joint in it's original
position.
NOTE: Verify boot is not twisted and remove any
excess air.
(13) Secure both boot clamps (Fig. 15) with Clamp
Installer C-4975A. Place tool on clamp bridge and
tighten tool until jaws of the tool are closed.
Fig. 12 BEARING CAGE AND HOUSING
1 - OUTER RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
Fig. 13 BALL BEARING
1 - C/V HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BEARING
Fig. 14 OUTER C/V JOINT
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 15 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
3 - 24 HALF SHAFTDR
CV JOINT-OUTER (Continued)

(8) Position the boot on the joint and shaft in it's
original position (Fig. 21).
NOTE: Verify boot is not twisted and remove any
excess air.
(9) Measure the distance from the end of the hous-
ing to the end of the boot on the shaft. This measure-
ment should be 260 mm (10.25 in.).NOTE: If measurement is not correct, allow more or
less air into the boot.
(10) Secure both boot clamps with Clamp Installer
C-4975A. Place tool on clamp bridge and tighten tool
until the jaws of the tool are closed.
Fig. 20 HOUSING BUSHING
1 - BUSHING
2 - HOUSING
Fig. 21 INNER C/V BOOT
1 - CLAMP
2 - BOOT
3 - CLAMP
4 - SHAFT
5 - HOUSING
3 - 26 HALF SHAFTDR
CV JOINT-INNER (Continued)

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceNew Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 8177,
Arbor Discs 8541 and Dial Indicator C-3339 (Fig. 7).(1) Assemble Pinion Height Block 6739, Pinion
Block 8177 and rear pinion bearing onto Screw 6741
(Fig. 7).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through the
pinion bearing cups (Fig. 8).
(3) Install front pinion bearing and Cone-Nut 6740
onto the screw. Tighten cone-nut until Torque To
Rotate the screw is 2.0 N´m (18 in. lbs.) (Fig. 7).
(4) Place Arbor Discs 8541 on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 9).
Install differential bearing caps on arbor discs and
tighten cap bolts to specification.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
Fig. 7 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 8 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
DRFRONT AXLE - C205F 3 - 33
FRONT AXLE - C205F (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
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.
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) With vehicle in neutral, position vehicle on
hoist.
(2) Remove brake calipers and rotors.
(3) Disconnect ABS wheel speed sensors.
(4) Disconnect axle vent hose.
(5) Remove front propeller shaft.
(6) Remove stabilizer bar links at the axle brack-
ets (Fig. 1).
(7) Disconnect shock absorbers from axle brackets
(Fig. 2).
(8) Remove track bar from the axle bracket (Fig.
3).
(9) Remove tie rod and drag link (Fig. 4) from the
steering knuckles.
(10) Position lift under the axle assembly and
secure axle to lift.
(11) Mark suspension alignment cams for installa-
tion reference.
Fig. 1 STABILIZER LINK
1 - PULLER C-3894-A
2 - LINK
DRFRONT AXLE - 9 1/4 AA 3 - 57
FRONT AXLE - 9 1/4 AA (Continued)

(12) Remove upper and lower suspension arms
from the axle bracket (Fig. 5).
(13) Lower the axle. The coil springs will drop
with the axle.
(14) Remove coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of thevehicle on the suspension. Failure to heed caution
may result in damage.
(1) Support the axle on a suitable lifting device.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
Fig. 2 SHOCK ABSORBER
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - BOLT
3 - NUT
Fig. 4 DRAG LINK
1 - PITMAN ARM
2 - DRAGLINK
3 - PULLER C-3894-A
Fig. 5 LINK/COIL SUSPENSION
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
3 - 58 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 68 N´m (50 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 108 N´m (80 ft.
lbs.).
(11) Install ABS wheel speed sensors.
(12) Install rotors and brake calipers.
(13) Connect the axle vent hose.
(14) Install front propeller shaft.
(15) With vehicle on the ground, tighten upper
suspension arm nuts at axle to 149 N´m (110 ft. lbs.).
Tighten upper suspension arm nuts at frame to 149
N´m (110 ft. lbs.).
(16) With vehicle on the ground, tighten lower sus-
pension arm nuts at axle to 190 N´m (140 ft. lbs.).
Tighten the lower suspension arm nuts at frame to
190 N´m (140 ft. lbs.).
(17) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(18) Check front wheel alignment.
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. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8878 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(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.).
(4) Place Arbor Disc 8289 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 85 N´m (63 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor disc.
(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.
Fig. 6 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. 7 PINION HEIGHT BLOCK
1. PINION HEIGHT BLOCK
2. PINION BLOCK
DRFRONT AXLE - 9 1/4 AA 3 - 59
FRONT AXLE - 9 1/4 AA (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
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 lift under axle and secure axle to
lift.
(3) Remove wheels and tires assemblies.
(4) Remove all brake components.
(5) Remove axle vent hose.
(6) Mark propeller shaft and companion flange for
installation alignment reference.
(7) Remove propeller shaft.
(8) Remove shock absorbers from axle (Fig. 1).
(9) Remove U-bolts from axle (Fig. 2).
(10) Remove axle from the vehicle.
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 comonents.
(5) Install axle vent hose.
(6) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(7) Install the wheels and tires.
(8) Fill differential to specifications.
(9) Remove lift from axle and lower the vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets.
Identifying numbers for the ring gear and pinion are
painted onto the pinion gear shaft (Fig. 3) and the
side of the ring gear. A plus (+) number, minus (±)
DRREAR AXLE - 9 1/4 3 - 83
REAR AXLE - 9 1/4 (Continued)

(4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 7).
Install differential bearing caps on arbor discs and
tighten cap bolts to 41 N´m (30 ft. lbs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 5). Hold scooter block in place and
zero the dial indicator. Tighten dial indicator face
lock screw.
(7) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 8). Continue moving the dial probe to the crest
of the arbor bar and record the highest reading.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
marked on the shaft of the pinion. For example, if
the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
The following must be considered when adjusting
bearing preload and gear backlash:
²The maximum ring gear backlash variation is
0.076 mm (0.003 in.).
²Mark the gears so the same teeth are meshed
during all backlash measurements.
²Maintain the torque while adjusting the bearing
preload and ring gear backlash.
²Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure.
Insufficient adjuster torque can result in excessive
differential case free-play and ring gear noise.
²Insufficient adjuster torque will not support the
ring gear correctly and can cause excessive differen-
tial case free-play and ring gear noise.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
²Maintain the gear teeth engaged (meshed) as
marked.
²The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
²Do this five to ten times each time the threaded
adjusters are adjusted.
Fig. 7 PINION DEPTH TOOLS
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 8 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
3 - 86 REAR AXLE-91/4DR
REAR AXLE - 9 1/4 (Continued)