1998 DODGE RAM 1500 differential

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)

DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover and drain
fluid.
(2) Remove axle shafts.
(3) Loosen bearing cap bolts.
NOTE: Differential bearing cap reference numbers
are stamped on caps and machined flat on the
housing. If reference numbers cannot be found,
make new marks for later reference.
(4) Install Adapter Plates 8142-A onto the housing.
(5) Install Spreader W-129-B onto the adapter
plates (Fig. 37) and tighten the turnbuckle finger-
tight.
(6) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
(7) Spread the housing to remove the differential
case from the housing (Fig. 38). Measure the distance
with the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(8) Remove dial indicator.
(9) While holding the differential case in position,
remove bearing cap bolts and caps.(10) Remove differential from the housing (Fig.
39). Ensure differential bearing cups and shims
remain in position on the differential bearings.
(11) Tag differential bearing cups and shims to
indicate their location.
Fig. 36 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCHFig. 37 ADAPTER PLATES AND SPREADER
1 - ADAPTER PLATE
2 - SPREADER
Fig. 38 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - SPREADER
3 - 46 FRONT AXLE - C205FDR
PINION SEAL (Continued)

(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears (2) and remove
pinion gears (3) and thrust washers (1) (Fig. 40).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their original locations.
(1) Lubricate differential components with hypoid
gear lubricant.
(2) Install side gears and thrust washers into the
differentail case.
(3) Rotate pinion mate gears and thrust washers
into the differentail case.
(4) Install pinion gear mate shaft.
(5) Align hole in pinion gear mate shaft with hole
in the differential case.
(6) Install roll-pin (3) in the differential case with
a punch (1) and hammer (Fig. 41). Peen edge of roll-
pin hole in differential case in two places 180É apart.
(7) Install ring gear.
Fig. 39 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 40 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 41 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
DRFRONT AXLE - C205F 3 - 47
DIFFERENTIAL (Continued)

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader W-129-B with the Adapter
Plates 8142-A and install the safety holddown
clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread housing over 0.50 mm
(0.020 in). Failure to heed caution may result in
damage.
(4) Remove dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain in position on the
bearings and the differential preload shims are
seated in the housing. Tap differential case to ensure
bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader.
(8) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(9) Install axle shafts.
(10) Apply a bead of orange Mopar Axle RTV seal-
ant or equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied. Failure to heed caution may result in dam-
age.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N´m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings (3) from differential case (4)
with Puller C-293-PA (1) Adapters C-293-48 (2) and
Plug C-293-3 (5) (Fig. 42).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 43).
(2) Install differential into the housing.
Fig. 42 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 48 FRONT AXLE - C205FDR
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft jaw
(Fig. 44).
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 44).
(5) Mark companion yoke and companion flange
for installation reference.
(6) Remove companion flange bolts and tie the pro-
peller shaft to the vehicle underbody.
(7) Rotate companion flange three or four times
and verify flange rotates smoothly.
(8) Record pinion rotating torque an inch pound
torque wrench for installation reference (Fig. 45).
(9) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(10) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so that
the Holder 6719 is held to the flange.(11) Remove the pinion nut.
(12) Remove the companion flange with Remover
C-452 (Fig. 46).
(13) Remove pinion from differential housing.
(14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
(15) Remove oil slinger, if equipped and front pin-
ion bearing.
(16) Remove front pinion bearing cup with
Remover 8831 and Handle C-4171 (Fig. 47).
Fig. 43 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 44 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 45 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 49
DIFFERENTIAL CASE BEARINGS (Continued)

(15) Invert differential case and start two ring
gear bolts to provide ring gear bolt hole alignment.
(16) Invert differential case in the vise.
(17) Installnewring gear bolts and alternately
tighten to 108 N´m (80 ft. lbs.) (Fig. 58).
CAUTION: Never reuse the ring gear bolts. Failure
to heed caution may result in damage.
(18) Install differential in housing and verify gear
mesh, backlash and contact pattern.
Fig. 56 PINION NUT
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 57 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 58 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
DRFRONT AXLE - C205F 3 - 53
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

Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 56 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)