1998 DODGE RAM 1500 Tie

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)

(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)

INSTALLATION
(1) Install differential side bearings (3) with
Installer C-4213 (4) and Handle C-4171 (1) (Fig. 53).
(2) Install differential case into housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts.
(4) Remove differential from the differential hous-
ing.
(5) Place differential case in a vise with soft metal
jaw protectors..
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 54).(8) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(9) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
(11) Remove companion flange with Remover
C-452 (Fig. 55).
Fig. 53 DIFFERENTIAL CASE BEARING
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 54 RING GEAR
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 55 COMPANION FLANGE
1 - COMPANION FLANGE
2 - REMOVER
3 - 106 REAR AXLE-91/4DR
DIFFERENTIAL CASE BEARINGS (Continued)

INSTALLATION
(1) Install fan blade assembly to electrically con-
trolled viscous fan drive. Tighten mounting bolts to
24 N´m (18 ft. lbs.) torque.
(2) Position the fan blade/viscous fan drive to the
vehicle as an assembly.
(3) Install the viscous fan drive assembly onto fan
pulley hub shaft (Fig. 4). Tighten mounting nut to
115 N´m (85 ft. lbs.) torque.
(4) Install upper fan shroud. Make sure the upper
shroud locks into the tabs on the lower radiator.
(5) Install two upper shroud mounting bolts.
Tighten to 11.8 N´m (105 in. lbs.) torque.
(6) Position the electronically controlled viscous
fan drive wiring into the channel in the upper fan
shroud (Fig. 5). Make sure the wiring is not pinched.
(7) Install the lower fan shroud into position and
verify the two locking tabs have seated.
(8) Install two push pin fasteners to lock lower fan
shroud to the main assembly.
NOTE: Verify that the fan drive electrical wire does
not interfere with fan blade travel when the fan
blade is spun by hand.
(9) Connect the wiring harness connector and
install the harness bracket to the upper radiator
shroud.(10) Install the coolant recovery container (Refer to
7 - COOLING/ENGINE/COOLANT RECOVERY
CONTAINER - INSTALLATION).
(11) Connect the battery negative cables.
NOTE:
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the
engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
ENGINE BLOCK HEATER
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An optional engine block heater is available with
all models. The heater is equipped with a power cord.
The cord is attached to an engine compartment com-
ponent with tie-straps. The heater warms the engine
providing easier engine starting and faster warm-up
in low temperatures. The heater is mounted in a core
hole of the engine cylinder block in place of a freeze
plug with the heating element immersed in engine
coolant. The 3.7L/4.7L gas powered engines have the
block heater located to the rear on the right side of
the engine (Fig. 6).
OPERATION
The heater warms the engine coolant providing
easier engine starting and faster warm-up in low
temperatures. Connecting the power cord to a
grounded 110-120 volt AC electrical outlet with a
grounded three wire extension cord provides the elec-
tricity needed to heat the element.
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER
If the unit does not operate, possible causes can be
either the power cord or the heater element. Test the
power cord for continuity with a 110-volt voltmeter or
110-volt test light. Test heater element continuity
with an ohmmeter or a 12-volt test light.
CAUTION: To prevent damage, the power cord must
be secured in it's retainer clips and away from any
components that may cause abrasion or damage,
such as linkages, exhaust components, etc.
Fig. 5 Electronically Controlled Viscous Fan Drive
Wiring
1 - UPPER SHROUD
2 - WIRING
3 - GROMMET
7 - 36 ENGINEDR
RADIATOR FAN - 5.9L DIESEL (Continued)

REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain the coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the power cord from the heater by
unplugging (Fig. 7).
(4) Loosen (but do not completely remove) the
screw at center of block heater (Fig. 7).
(5) Remove the block heater by carefully prying
from side-to-side. Note the direction of the heating
element coil (up or down). The element coil must be
installed correctly to prevent damage.
INSTALLATION
(1) Clean and inspect the block heater hole.
(2) Install the new O-ring seal(s) to heater.
(3) Insert the block heater into cylinder block and
position the element properly.
(4) With the heater fully seated, tighten center
screw to 2 N´m (17 in. lbs.).
(5) Fill the cooling system with the recommended
coolant. (Refer to 7 - COOLING - STANDARD PRO-
CEDURE).
(6) Start and warm the engine.
(7) Check the block heater for leaks.
ENGINE BLOCK HEATER - 5.9L
DIESEL
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST BE SECURED IN ITS
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An optional engine block heater is available on all
models. The heater is equipped with a power cord.
The heater is mounted in a threaded hole of the
engine cylinder block with the heating element
immersed in engine coolant. The cord is attached to
an engine compartment component with tie-straps.
The 5.9L diesel engine has the block heater located
on the right side of the engine below the exhaust
manifold next to the oil cooler (Fig. 8).
Fig. 6 Engine Block Heater - 3.7L/4.7L
1 - ENGINE BLOCK HEATER
Fig. 7 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
DRENGINE 7 - 37
ENGINE BLOCK HEATER (Continued)

antenna body to fender mating surfaces and tighten
the antenna cap nut to specifications.
(4) Check the resistance again with an ohmmeter.
If the resistance is still more then one ohm, replace
the faulty antenna body and cable.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right side kick panel.
(3) Disconnect antenna body cable from instru-
ment panel cable.
(4) Securely tie a suitable length of cord or twine
to the antenna half of the coaxial cable connector.
This cord will be used to pull the cable back into
position during installation.
(5) Remove the antenna mast.
(6) Remove the antenna cap nut using an antenna
nut wrench (Special Tool C-4816) (Fig. 3).
(7) Remove the antenna adapter.
(8) With the right door open, pull the antenna
body assembly out through the opening between the
fender and body.
INSTALLATION
(1) Tie the cord that was used during the removal
procedure to the cable being installed.
(2) Using the cord, pull the antenna cable through
the hole in the door opening and seat grommet into
place.
(3) Connect the antenna body and cable to the
instrument panel cable.
(4) Install the right side kick panel.(5) Insert the antenna body through the hole in
the fender and install adapter.
(6) Install the antenna cap nut. Tighten to 7 N´m
(65 in. lbs.).
(7) Install the antenna mast.
(8) Connect the battery negative cable.
ANTENNA - NAVIGATION
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel top cover (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL).
(3) Remove the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
(4) Remove the antenna mounting fasteners (Fig.
4).
(5) Cut each end of the cable and leave remaining
portion in the instrument panel (Fig. 5).
INSTALLATION
(1) Position new antenna cable to wire harness.
Secure into place.
(2) Install antenna mounting fasteners.
(3) Install radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION).
(4) Install instrument panel top cover (Refer to 23
- BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION).
Fig. 3 ANTENNA BODY AND CABLE
1 - NUT
2 - FENDER
3 - ANTENNA BODY AND CABLE
4 - ADAPTER
Fig. 4 NAVIGATION ANTENNA MOUNTING
8A - 6 AUDIO/VIDEODR
ANTENNA BODY & CABLE (Continued)

REMOTE RADIO SWITCH TEST TABLE
Switch Switch Position Resistance
Right
(White)Volume Up1.210 Kilohms
 1%
Right
(White)Volume Down3.010 Kilohms
 1%
Right
(White)Mode Advance0.0511 Kilohms
 1%
Left
(Black)Seek Up0.261 Kilohms
 1%
Left
(Black)Seek Down0.681 Kilohms
 1%
Left
(Black)Pre-Set Station
Advance0.162 Kilohms
 1%
(3) Reconnect the battery negative cable. Turn the
ignition switch to the On position. Check for 5 volts
at the radio control mux circuit cavities of the steer-
ing wheel wire harness connectors for both remote
radio switches. If OK, go to Step 4. If not OK, repair
the open or shorted radio control mux circuit to the
Integrated Power Module (IPM) as required.
(4) Disconnect and isolate the battery negative
cable. Disconnect the 22-way instrument panel wire
harness connector from the IPM. Check for continu-
ity between the remote radio switch ground circuit
cavities of the steering wheel wire harness connec-
tors for both remote radio switches and a good
ground. There should be no continuity. If OK, go to
Step 5. If not OK, repair the shorted remote radio
switch ground circuit to the IPM as required.
(5) Check for continuity between the remote radio
switch ground circuit cavities of the steering wheel
wire harness connectors for both remote radio
switches and the 22-way instrument panel wire har-
ness connector for the IPM. There should be continu-
ity. If OK, refer to the proper Diagnostic Procedures
manual to test the IPM and the PCI data bus. If not
OK, repair the open remote radio switch ground cir-
cuit as required.
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAGSYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the driver airbag from the vehicle
(Refer to 8 - ELECTRICAL/RESTRAINTS/DRIVER
AIRBAG - REMOVAL).
(3) Remove the speed control switches (Refer to 8 -
ELECTRICAL/SPEED CONTROL/SWITCH -
REMOVAL).
(4) Unplug the wire harness connector from the
remote radio switch(es).
(5) Depress the tabs on each side of each switch
and push the switch through the rear steering wheel
cover (Fig. 16).
INSTALLATION
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 16 REMOTE SWITCHES
1 - REMOTE SWITCH
2 - SPEED CONTROL SWITCH
3 - BOLT
8A - 12 AUDIO/VIDEODR
REMOTE SWITCHES (Continued)

(1) Install remote radio switch to the steering
wheel.
(2) Connect the wire harness to the remote radio
switch.
(3) Install the speed control switches (Refer to 8 -
ELECTRICAL/SPEED CONTROL/SWITCH -
INSTALLATION).
(4) Install the driver airbag
(5) Connect the battery negative cable.
SPEAKER
DESCRIPTION
STANDARD
The standard equipment speaker system includes
speakers in four locations. One 15.2 X 22.8 centime-
ter (6 X 9 inch) full-range speaker is located in each
front door. There is also one full-range 13.3 centime-
ter (5.25 inch) diameter full-range speaker located in
each rear door.
PREMIUM
The optional premium speaker system features
eleven Premium model speakers in seven locations.
Each of the standard speakers is replaced with Pre-
mium model speakers. One 8.8 centimeter (3.50 inch)
diameter speaker is located on each end of the
instrument panel top pad. One 6.3 centimeter (2.50
inch) diameter speaker is located in the center of the
instrument panel top pad. One 15.2 X 22.8 centime-
ter (6 X 9 inch) Premium speaker is located in each
front door. There is also one coaxial 13.3 centimeter
(5.25 inch) diameter Premium full-range speaker
located in each rear door. The premium speaker sys-
tem also includes a power amplifier mounted behind
the glove box. The total available power of the pre-
mium speaker system is 240 watts.
OPERATION
Two wires connected to each speaker, one feed cir-
cuit (+) and one return circuit (±), allow the audio
output signal electrical current to flow through the
voice coil. For complete circuit diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
DIAGNOSIS AND TESTING - SPEAKER
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the
DRB IIIt, refer to the appropriate Diagnostic
Service Manual.
Refer to the appropriate wiring information.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
ªfloating groundº system. Do not allow any speaker
lead to short to ground, as damage to the radio
and/or amplifier may result.
(1) If all speakers are inoperative, check the fuses
in the Integrated Power Module (IPM). If OK, go to
Step 2. If not OK, repair the shorted circuit or com-
ponent as required and replace the faulty fuse.
(2) Check the amplifier fuse (if equipped) in the
IPM. If OK, go to Step 3. If not OK, repair the
shorted circuit or component as required and replace
the faulty fuse.
(3) Turn the ignition switch to the ON position.
Turn the radio receiver ON. Adjust the balance and
fader control controls to check the performance of
each individual speaker. Note the speaker locations
that are not performing correctly. Go to Step 4.
(4) Turn the radio receiver OFF. Turn the ignition
OFF. Disconnect and isolate the battery negative
cable. If vehicle isnotequipped with a amplifier,
remove the radio receiver. If vehicle is equipped with
an amplifier. disconnect wire harness connector at
output side of amplifier. Go to Step 5.
(5) Check both the speaker feed (+) circuit and
return (-) circuit cavities for the inoperative speaker
at the radio receiver wire harness connector for con-
tinuity to ground. There should be no continuity. If
OK, go to Step 6. If not OK, repair the shorted
speaker feed (+) and/or return (-) circuits(s) to the
speaker as required.
DRAUDIO/VIDEO 8A - 13
REMOTE SWITCHES (Continued)