1998 DODGE RAM 1500 Alignment

(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)

VIBRATION
Vibration at the front/rear of the vehicle is usually
caused by:
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 vibration. Do
not overlook engine accessories, brackets and drive
belts.
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 and lis-
ten 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.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace 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.
DRFRONT AXLE - 9 1/4 AA 3 - 55
FRONT AXLE - 9 1/4 AA (Continued)

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.
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) With vehicle in neutral, position vehicle on
hoist.
(2) Remove brake calipers and rotors.
(3) Disconnect ABS wheel speed sensors.
(4) Disconnect axle vent hose.
(5) Remove front propeller shaft.
(6) Remove stabilizer bar links at the axle brack-
ets (Fig. 1).
(7) Disconnect shock absorbers from axle brackets
(Fig. 2).
(8) Remove track bar from the axle bracket (Fig.
3).
(9) Remove tie rod and drag link (Fig. 4) from the
steering knuckles.
(10) Position lift under the axle assembly and
secure axle to lift.
(11) Mark suspension alignment cams for installa-
tion reference.
Fig. 1 STABILIZER LINK
1 - PULLER C-3894-A
2 - LINK
DRFRONT AXLE - 9 1/4 AA 3 - 57
FRONT AXLE - 9 1/4 AA (Continued)

(12) Remove upper and lower suspension arms
from the axle bracket (Fig. 5).
(13) Lower the axle. The coil springs will drop
with the axle.
(14) Remove coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of thevehicle on the suspension. Failure to heed caution
may result in damage.
(1) Support the axle on a suitable lifting device.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
Fig. 2 SHOCK ABSORBER
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - BOLT
3 - NUT
Fig. 4 DRAG LINK
1 - PITMAN ARM
2 - DRAGLINK
3 - PULLER C-3894-A
Fig. 5 LINK/COIL SUSPENSION
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
3 - 58 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 68 N´m (50 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 108 N´m (80 ft.
lbs.).
(11) Install ABS wheel speed sensors.
(12) Install rotors and brake calipers.
(13) Connect the axle vent hose.
(14) Install front propeller shaft.
(15) With vehicle on the ground, tighten upper
suspension arm nuts at axle to 149 N´m (110 ft. lbs.).
Tighten upper suspension arm nuts at frame to 149
N´m (110 ft. lbs.).
(16) With vehicle on the ground, tighten lower sus-
pension arm nuts at axle to 190 N´m (140 ft. lbs.).
Tighten the lower suspension arm nuts at frame to
190 N´m (140 ft. lbs.).
(17) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(18) Check front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets. Compensation for pinion depth variance is
achieved with a select shim. located between the rear
pinion bearing and pinion gear head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8878 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone-Nut 6740
onto the screw. Tighten cone-nut until Torque To
Rotate the screw is 1.7-2.26 N´m (15-20 in. lbs.).
(4) Place Arbor Disc 8289 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 85 N´m (63 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor disc.
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
Fig. 6 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 7 PINION HEIGHT BLOCK
1. PINION HEIGHT BLOCK
2. PINION BLOCK
DRFRONT AXLE - 9 1/4 AA 3 - 59
FRONT AXLE - 9 1/4 AA (Continued)

(20) Fill differential with lubricant, refer to Lubri-
cation & Maintenance for capacity and lubricant
type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove the differential case from the housing.
(2) Install Plug 8888 into the end of the case.
(3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 43).
INSTALLATION
(1) Set differential case on Plug 8888.
(2) Install differenial case bearings with Installer
8881 and Handle C-4171 (Fig. 44).
(3) Install differentail case into housing.
PINION GEAR/RING GEAR
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 axle shafts.
(4) Remove differential from housing.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.
Fig. 43 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
Fig. 44 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
DRFRONT AXLE - 9 1/4 AA 3 - 75
DIFFERENTIAL (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)

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)