1998 DODGE RAM 1500 fig

CLEANING
Clean the differential case and gears with light oil
or a lint free cloth.
NOTE: Never use water, steam, kerosene or gaso-
line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be
smoothed with 400 grit emery cloth and polished
out with crocus cloth.
(1) Inspect pinion gears teeth for chips and cracks
(Fig. 42).
(2) Inspect pinion gears shafts and brake shoes for
scratches, flat-spots or worn (Fig. 42).
(3) Inspect side gears teeth for chips and cracks
(Fig. 43).
(4) Inspect pinion and side gear bores for scratches
(Fig. 44).
NOTE: If any damage is found the differential must
be replaced as an assembly. Individual components
can not be replaced separately.
Fig. 42 PINION GEAR AND BRAKE SHOE
1 - BRAKE SHOES
2 - PINION GEAR
3 - PINION SHAFT
Fig. 43 SIDE GEARS
1 - THRUST WASHERS
2 - SPACER
3 - SIDE GEARS
Fig. 44 PINION/SIDE GEAR BORE
1 - PINION BORES
2 - SIDE GEAR BORE
3 - 160 REAR AXLE - 11 1/2 AADR
DIFFERENTIAL TRAC-RITE (Continued)

ASSEMBLY
NOTE: Install all component in their original loca-
tions.
(1) Lubricate all gears and differential bores with
differential lubricant.
(2) Install one set of pinion brake shoes into the
case bores.
NOTE: Brake shoes can be installed upside down,
but if install wrong pinion gear will not fit.
(3) Install side gear thrust washer, side gear and
spacer (Fig. 45).
(4) Install one set of pinion gears into the bores
next to the brake shoes, with the pinion shaft facing
up.
(5) Install other side gear and thrust washer.
(6) Install other set of pinion gears into the brake
shoes in the case.(7) Install other set of brake shoes onto the pinion
gears shafts (Fig. 46).
(8) Install differential cover and location screws.
(9) Installnewring gear bolts and tighten to 237
N´m (175 ft. lbs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from the housing.
(2) Install Plug 8964 into the end of the case.
(3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 47).
INSTALLATION
(1) Install differenial case bearings with Installer
8965 and Handle C-4171 (Fig. 48).
(2) Install differentail case into housing.
Fig. 45 SIDE GEAR AND SPACER
1 - SPACER
2 - SIDE SPACER
Fig. 46 PINION BRAKE SHOES
1 - BRAKE SHOES
2 - PINION GEARS
DRREAR AXLE - 11 1/2 AA 3 - 161
DIFFERENTIAL TRAC-RITE (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from the housing.
(4) Place differential on Plug 8964. Drive exciter
ring off the differential case with a hammer and
punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flange nut.
(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 52).
Fig. 47 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
Fig. 48 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
3 - 162 REAR AXLE - 11 1/2 AADR
DIFFERENTIAL CASE 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)

(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 237 N´m (175 ft.
lbs.).
(19) If exciter ring was removed, position differen-
tial assembly on differential Plug 8965 (Fig. 64) and
place exciter ring on the differential case.
(20) Install the exciter ring on the differential case
evenly with a hammer and brass punch (Fig. 65).Drive the ring down until it is seated against the
ring gear.
CAUTION: Do not damage exciter ring teeth during
installation.
Fig. 62 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 63 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 64 EXCITER RING
1 - EXCITER RING
2 - RING GEAR
3 - DIFFERENTIAL PLUG
4 - DIFFERENTIAL CASE
Fig. 65 EXCITER RING INSTALLATION
1 - EXCITER RING
2 - PUNSH
3 - RING GEAR
3 - 166 REAR AXLE - 11 1/2 AADR
PINION GEAR/RING GEAR/TONE RING (Continued)

of chatter are out-of-tolerance rotors, brake lining not
securely attached to the shoes, loose wheel bearings
and contaminated brake lining.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre-
quentlynotcaused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
a thump or clunk noise.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
(1) Remove reservoir filler caps and fill reservoir.
(2) If calipers were overhauled, open all caliper
bleed screws. Then close each bleed screw as fluid
starts to drip from it. Top off master cylinder reser-
voir once more before proceeding.
(3) Attach one end of bleed hose to bleed screw
and insert opposite end in glass container partially
filled with brake fluid (Fig. 1). Be sure end of bleed
hose is immersed in fluid.
NOTE: Bleed procedure should be in this order (1)
Right rear (2) Left rear (3) Right front (4) Left front.(4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down close
the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
wheel.
(5) Before moving the vehicle verify the pedal is
firm and not mushy.
(6) Top off the brake fluid and install the reservoir
cap.
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at
all times.
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 15-20 psi is sufficient for
bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl-
inder adapter. The wrong adapter can lead to leak-
age, or drawing air back into the system.
SPECIAL TOOLS
BASE BRAKES
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
INSTALLER, BRAKE CALIPER DUST BOOT C-4340
INSTALLER, BRAKE CALIPER DUST BOOT
C-3716-A
DRBRAKES - BASE 5 - 5
BRAKES - BASE (Continued)