1998 DODGE RAM 1500 Washer

(7) Drive ring gear from differential case with a
soft hammer (Fig. 45).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 46) and remove pinion flange nut and washer.(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 47).
(10) Remove pinion gear from housing with Pinion
Driver 8976 and a hammer (Fig. 48).
NOTE: Thread drive on shaft until it bottoms out.
Fig. 45 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 46 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 47 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 48 PINION DRIVER
1 - PINION SHAFT
2 - PINION DRIVER
3 - 76 FRONT AXLE - 9 1/4 AADR
PINION GEAR/RING GEAR (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)

LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint.
²Worn side gear thrust washers.
²Worn pinion shaft bore.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
DRREAR AXLE - 9 1/4 3 - 81
REAR AXLE - 9 1/4 (Continued)

SIDE GEAR CLEARANCE
When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install the axle shafts and C-locks and pinion
mate shaft.
(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 17).(3) If side gear clearances is no more than 0.005
inch. Determine if the axle shaft is contacting the
pinion mate shaft.Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear.If the end of
the axle shaft is not contacting the pinion mate
shaft, the side gear clearance is acceptable.
(4) If clearance is more than 0.005 inch (axle shaft
not contacting mate shaft), record the side gear clear-
ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick-
ness to the recorded side gear clearance. The sum of
gear clearance and washer thickness will determine
required thickness of replacement thrust washer
(Fig. 18).
In some cases, the end of the axle shaft will move
and contact the mate shaft when the feeler gauge is
inserted. The C-lock is preventing the side gear from
sliding on the axle shaft.
(5) If there is no side gear clearance, remove the
C-lock from the axle shaft. Use a micrometer to mea-
sure the thrust washer thickness. Record the thick-
ness and re-install the thrust washer. Assemble the
differential case without the C-lock installed and re-
measure the side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-lock was installed to
thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
Fig. 16 HIGH PINION HEIGHT
Fig. 17 SIDE GEAR CLEARANCE
1 - FEELER GAUGE
2 - SIDE GEAR
Fig. 18 SIDE GEAR CALCULATIONS
DRREAR AXLE - 9 1/4 3 - 89
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)

(8) Remove pinion seal with pry tool or slide-ham-
mer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with Installer C-3860-A
and Handle C-4171 (Fig. 26)
(3) Install companion flange on the end of the
shaft with the reference marks aligned.
(4) Install two bolts into the threaded holes in the
companion flange, 180É apart.
(5) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so holder
is held to the flange.
(6) Install companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Install pinion washer and anewpinion nut.
The convex side of the washer must face outward.
CAUTION: Never exceed the minimum tightening
torque 285 N´m (210 ft. lbs.) when installing the
companion flange retaining nut at this point. Dam-
age to collapsible spacer or bearings may result.
(8) Hold companion flange with Holder 6719 and
tighten the pinion nut with a torque set to 285 N´m
(210 ft. lbs.) (Fig. 27). Rotate pinion several revolu-
tions to ensure the bearing rollers are seated.
(9) Rotate pinion with an inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N´m (5 in. lbs.) (Fig. 28).CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.
Fig. 26 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
3 - HOUSING
Fig. 27 TIGHTENING PINION NUT
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 28 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - TORQUE WRENCH
3 - 96 REAR AXLE-91/4DR
PINION SEAL (Continued)

(9) Loosen differential bearing adjusters through
the axle tubes with Wrench C-4164 (Fig. 31).
(10) Hold differential case while removing bearing
caps and adjusters.
(11) Remove differential case.
NOTE: Tag the differential bearing cups and
threaded adjusters to indicate their location.
DISASSEMBLY
(1) Rotate one pinion gear (2) with thrust washer
(3) (Fig. 32) to the differential window (1) and
remove gear and thrust washer.
(2) Rotate remaining pinion gear (3) with thrust
washer (2) (Fig. 33) to the differential window (1)
and remove gear and washer.
(3) Remove differential side gears (1) (2) and
thrust washers (Fig. 34).
Fig. 31 THREADED ADJUSTER TOOL
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
Fig. 32 FRIST PINION GEAR
1 - DIFFERNTIAL CASE WINDOW
2 - PINION GEAR
3 - THRUST WASHER
Fig. 33 SECOND PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - THRUST WASHER
3 - PINION GEAR
Fig. 34 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
3 - 98 REAR AXLE-91/4DR
DIFFERENTIAL (Continued)