1998 DODGE RAM 1500 Rear brake

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)

(1) Through the axle tube use Wrench C-4164 to
adjust each threaded adjuster inward until the differ-
ential bearing free-play is eliminated. Allow some
ring gear backlash approximately 0.25 mm (0.01 in.)
between the ring and pinion gear. Seat the bearing
cups with the procedure described above.
(2) Install dial indicator and position the plunger
against the drive side of a ring gear tooth (Fig. 9).
Measure the backlash at 4 positions, 90 degrees
apart around the ring gear. Locate and mark the
area of minimum backlash.
(3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
measurements will be taken with the same gear
teeth meshed.
(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.076 to 0.102
mm (0.003-0.004 in.) with each adjuster tightened to
14 N´m (10 ft. lbs.). Seat the bearing cups with the
procedure described above.
(5) Tighten the differential bearing cap bolts 136
N´m (100 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N´m (75 ft. lbs.). Seat the bearing cups with the pro-
cedure described above. Continue to tighten the
right-side adjuster and seat bearing cups until the
torque remains constant at 102 N´m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).(8) Continue increasing the torque at the right-
side threaded adjuster until the specified backlash is
obtained.
NOTE: The left-side threaded adjuster torque
should have approximately 102 N´m (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Tighten the left-side threaded adjuster until
102 N´m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(10) Install the threaded adjuster locks and
tighten the lock screws to 10 N´m (90 in. lbs.).
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 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 is correct (Fig. 10). Back-
lash and pinion depth is correct.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
Fig. 10 CORRECT CONTACT PATTERN
DRREAR AXLE - 9 1/4 3 - 87
REAR AXLE - 9 1/4 (Continued)

AXLE SHAFTS
REMOVAL
(1) Place transmission in neutral.
(2) Raise and support the vehicle.
(3) Remove wheel and tire assembly.
(4) Remove brake caliper, adapter and rotor (Fig.
19).(5) Remove differential housing cover and drain
lubricant.
(6) Rotate differential case so pinion mate shaft
lock screw is accessible. Remove lock screw and pin-
ion mate shaft from differential case (Fig. 20).
FIXTURE 8136
TRAC-LOK TOOLS 8139
ARBOR DISCS 8541
PINION BLOCK 8542
Fig. 19 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 20 PINION MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION MATE SHAFT
DRREAR AXLE - 9 1/4 3 - 93
REAR AXLE - 9 1/4 (Continued)

(7) Push axle shaft inward and remove axle shaft
C-lock from the axle shaft (Fig. 21).
(8) Remove axle shaft (Fig. 22) carefully to prevent
damage to the shaft bearing and seal in the axle
tube.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Insall axle shaft and engage into side gear
splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.(3) Insert C-lock in end of axle shaft then push
axle shaft outward to seat C-lock in side gear.
(4) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(5) Align hole in shaft with hole in the differential
case and install lock screw with Loctiteton the
threads. Tighten lock screw to 11 N´m (8 ft. lbs.).
(6) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
(7) Install brake rotor, caliper adapter and caliper.
(8) Install wheel and tire.
(9) Remove support and lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal (Fig. 23) from the axle
tube with a small pry bar.
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Coat the lip of thenewseal with axle lubricant
and install a seal with Installer C-4076-B and Han-
dle C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
Fig. 21 AXLE SHAFT C-LOCK
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 22 AXLE SHAFT
1 - AXLE SHAFT
2 - SUPPORT PLATE
3 - CALIPER
4 - PARK BRAKE SHOE ASSEMBLY
Fig. 23 AXLE SHAFT SEAL
1 - AXLE SEAL
2 - AXLE BEARING
3 - 94 REAR AXLE-91/4DR
AXLE SHAFTS (Continued)

(3) Install the axle shaft.
(4) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
AXLE BEARINGS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from axle tube with a
small pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove axle shaft bearing with Bearing
Remover 6310 and Foot 6310-9 (Fig. 24).
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install axle shaft bearing with Installer C-4198
and Handle C-4171. Drive bearing in until tool con-
tacts the axle tube.
NOTE: Bearing is installed with the bearing part
number against the installer.(3) Coat the lip of thenewaxle seal with axle
lubricant and install with Installer C-4076-B and
Handle C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
(4) Install the axle shaft.
(5) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
PINION SEAL
REMOVAL
(1) Mark universal joint, companion flange and
pinion shaft for installation reference.
(2) Remove propeller shaft from the companion
flange.
(3) Remove the brake rotors to prevent any drag.
(4) Rotate companion flange three or four times
and record pinion rotating torque with an inch pound
torque wrench.
(5) Install two bolts into the companion flange
threaded holes, 180É apart. Position Holder 6719A
against the companion flange and install and tighten
two bolts and washers into the remaining holes.
(6) Hold the companion flange with Holder 6719A
and remove pinion nut and washer.
(7) Remove companion flange with Remover C-452
(Fig. 25).
Fig. 24 AXLE SHAFT BEARING REMOVER
1 - AXLE SHAFT TUBE
2 - NUT
3 - GUIDE PLATE
4 - GUIDE
5 - THREADED ROD
6 - ADAPTER
7 - FOOT
Fig. 25 COMPANION FLANGE PULLER
1 - COMPANION FLANGE
2 - PULLER
DRREAR AXLE - 9 1/4 3 - 95
AXLE SHAFT SEALS (Continued)

(10) If rotating torque is low, use Holder 6719 to
hold the companion flange and tighten pinion nut in
6.8 N´m (5 ft. lbs.) increments until proper rotating
torque is achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
NOTE: The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N´m (210 ft.
lbs.).
(11) Install propeller shaft with the installation
reference marks aligned.
(12) Tighten the companion flange bolts to 108
N´m (80 ft. lbs.).
(13) Install brake rotors.
(14) Check the differential lubricant level.
DIFFERENTIAL COVER
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove drain plug.
(3) Remove cover bolts.
(4) Remove cover and drain lubricant.
INSTALLATION
(1) Apply a 6.35mm (1/4 in.) bead of Mopar Sili-
cone Rubber Sealant or equivalent to the housing
cover (Fig. 29).CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) Install cover and identification tag. Tighten
cover bolts in a criss-cross pattern to 41 N´m (30 ft.
lbs.).
(3) Fill differential to specifications.
(4) Install fill plug.
DIFFERENTIAL
REMOVAL
(1) Remove filler plug from the differential cover.
(2) Remove differential cover and drain the lubri-
cant.
(3) Clean housing cavity with flushing oil, light
engine oil or a lint free cloth.
NOTE: Do not use steam, kerosene or gasoline to
clean the housing.
(4) Remove axle shafts.
(5) Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark differential housing and bearing caps for
installation reference (Fig. 30).
(7) Remove bearing threaded adjuster lock from
each bearing cap.
(8) Loosen differential bearing cap bolts.
Fig. 29 COVER SEALANT
1 - SEALANT
2 - DIFFERENTIAL COVER
Fig. 30 REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARK
3 - BEARING CAPS
DRREAR AXLE - 9 1/4 3 - 97
PINION SEAL (Continued)

DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 41).
(6) If rotating torque is less than 41 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Holding Fixture 8136 in vise and set
differential case on fixture (Fig. 42).
(2) Remove pinion gear mate shaft screw.
(3) Remove pinion gear mate shaft.
Fig. 40 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 41 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 42 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
DRREAR AXLE - 9 1/4 3 - 101
DIFFERENTIAL-TRAC-LOK (Continued)

Condition Possible Causes Correction
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 lift to the
axle.
(3) Remove wheels and tires assemblies.
(4) Remove all brake components.
(5) Mark propeller shaft and companion flange for
installation alignment reference.
(6) Remove propeller shaft.
(7) Remove shock absorbers from axle (Fig. 1).
(8) Remove U-bolts from axle (Fig. 2).(9) Remove axle from the vehicle.
Fig. 1 SHOCK ABSORBER
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 2 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
4 - FRONT NUT & BOLT
5 - SPRING CLAMP BOLTS
6 - SHACKLES
DRREAR AXLE - 10 1/2 AA 3 - 115
REAR AXLE - 10 1/2 AA (Continued)