1998 DODGE RAM 1500 light

(23) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. Add the resulting measure-
ment to the thickness of the single dummy shim.
This is the thickness of shim required to achieve
proper backlash.
(24) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(25) Rotate dial indicator out of the way on pilot
stud.
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates
8142-A on the housing and spread open enough to
receive differential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the dial indicator plunger against a
ring gear tooth (Fig. 18).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the differential housing to the
other (Fig. 19).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern procedure.
GEAR 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 the 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. 20). Backlash
and pinion depth is correct.
Fig. 18 RING GEAR BACKLASH
1 - RING GEAR
2 - DIAL INDICATOR
Fig. 19 BACKLASH SHIM ADJUSTMENT
DRFRONT AXLE - C205F 3 - 37
FRONT AXLE - C205F (Continued)

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install seal with Installer 8695 and Handle
C-4171 (Fig. 34).
(3) Install companion flange onto the pinion with
Installer C-3718 and Holder 6719A.
(4) Position holder against the companion flange
and install four bolts and washers into the threaded
holes. Tighten the bolt and washer so that the holder
is held to the flange.
(5) Install anewpinion nut onto the pinion shaft
and tighten the pinion nut until there is zero bearing
end-play (Fig. 35).CAUTION: Do not exceed 271 N´m (200 ft. lbs.) the
minimum tightening torque when installing the
companion flange at this point. Failure to heed cau-
tion may result in damage.
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. Failure to heed caution may
result in damage.
(6) Record pinion rotating torque using an inch
pound torque wrench. The rotating torque should be
equal to the reading recorded during removal plus an
additional 0.56 N´m (5 in. lbs.) (Fig. 36).
(7) If rotating torque is low, tighten the pinion nut
in 6.8 N´m (5 ft. lbs.) increments until the proper
rotating torque is achieved.
CAUTION: If maximum tightening torque 475 N´m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Failure to heed caution may
result in damage.
(8) Install propeller shaft.
Fig. 33 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 COMPANION FLANGE HOLDER
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 45
PINION SEAL (Continued)

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 to Adjust-
ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of the bearing cups.
(2) Install rear pinion bearing cup with Installer
8692 and Driver Handle C-4171 (Fig. 51).
(3) Install front pinion bearing cup with Installer
8693 and Handle C-4171.
(4) Lubricate front pinion bearing and install bear-
ing in the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal.
(6) Install pinion seal with Installer 8695 and
Handle C-4171 (Fig. 52).
Fig. 50 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFTFig. 51 REAR PINION BEARING CUP
1 - HOUSING
2 - INSTALLER
3 - HANDLE
Fig. 52 PINION SEAL
1 - HANDLE
2 - INSTALLER
DRFRONT AXLE - C205F 3 - 51
PINION GEAR/RING GEAR (Continued)

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

(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 85 N´m (63 ft.
lbs.).
(13) Tighten adjuster lock bolts to 25 N´m (18 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.
11). 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 shortened 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 to specifica-
tion.
(4) Apply the brakes lightly to create a 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 is correct (Fig. 12). Back-
lash and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
13). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 14).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Ring gear too far away from pinion gear (Fig.
15). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 16).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
Fig. 11 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 12 CORRECT CONTACT PATTERN
Fig. 13 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
DRFRONT AXLE - 9 1/4 AA 3 - 61
FRONT AXLE - 9 1/4 AA (Continued)

(6) Hold pinion flange with Flange Wrench 8979
(Fig. 31) and remove pinion flange nut and washer.
(7) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 32).
(8) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8882 and
Handle C-4171 (Fig. 33).
(2) Apply a light coat of teflon thread sealant to
the pinion flange splines.(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
(5) Hold flange with Flange Wrench 8979 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. Tighten pinion nut in small incre-
ments, until pinion rotating torque is 0.40-0.57 N´m
(3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shafts and hub bearings.
(10) Install propeller shaft with reference marks
aligned.
Fig. 30 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 31 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 32 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 33 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
DRFRONT AXLE - 9 1/4 AA 3 - 71
PINION SEAL (Continued)

(4) Align hole in the pinion gears with hole in the
differential case.
(5) Install pinion shaft.
(6) Installnewpinion shaft lock bolt and tighten
to 52 N´m (38 ft. lbs.).
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
(4) Install bearing caps and bolts (Fig. 41). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 85 N´m (63 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 42).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts and hub bearings.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
Fig. 41 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTERFig. 42 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 74 FRONT AXLE - 9 1/4 AADR
DIFFERENTIAL (Continued)

(8) Installnewpinion seal (Fig. 56) with Installer
8882 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 shaft, until a few threads are show-
ing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
and tighten pinion nut until 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. 57). 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.)
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start twonewring gear bolts.
(17) Install the rest of thenewring gear bolts and
tighten them alternately to seat the ring gear.(18) Torque ring gear bolts to 140 N´m (103 ft.
lbs.).
(19) Install differential in housing.
(20) Measure final rotating torque with an inch
pound torque wrench. The final pinion rotating
torque plus differential case bearing preload is:
²New Bearings:3.4-5.6 N´m (30-50 in. lbs.)
²Original Bearings:2.8-5.1 N´m (25-45 in. lbs.)
(21) Install axle shafts.
(22) Verify ring gear backlash and gear contact
pattern.
(23) Install the propeller shaft with the reference
marks aligned.
(24) Install differential cover with gasket and
tighten to 40 N´m (30 ft. lbs.).
(25) Fill differential with fluid and tighten fill plug
to 32 N´m (24 ft. lbs.).
Fig. 56 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 57 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
DRFRONT AXLE - 9 1/4 AA 3 - 79
PINION GEAR/RING GEAR (Continued)