1998 DODGE RAM 1500 Removal

(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.
(11) Rotate case with turning bar until pinion
mate shaft holes in pinion gears align with holes in
case.
NOTE: It may be necessary to slightly tighten the
forcing screw in order to install the pinion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Discs and Threaded
Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft screw.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 52).
Fig. 51 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 52 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
DRREAR AXLE - 9 1/4 3 - 105
DIFFERENTIAL-TRAC-LOK (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)

REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page page
REAR AXLE - 10 1/2 AA
DIAGNOSIS AND TESTING...............112
REMOVAL............................115
INSTALLATION........................116
ADJUSTMENTS.......................116
SPECIFICATIONS......................120
SPECIAL TOOLS.......................120
AXLE SHAFTS
REMOVAL............................124
INSTALLATION........................124
AXLE BEARINGS
REMOVAL............................125
INSTALLATION........................125
PINION SEAL
REMOVAL............................126
INSTALLATION........................126
DIFFERENTIAL
REMOVAL............................127DISASSEMBLY........................128
ASSEMBLY...........................129
INSTALLATION........................130
DIFFERENTIAL TRAC-RITE
DESCRIPTION........................131
OPERATION..........................131
DISASSEMBLY........................131
CLEANING...........................132
INSPECTION.........................132
ASSEMBLY...........................133
DIFFERENTIAL CASE BEARINGS
REMOVAL............................134
INSTALLATION........................134
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................134
INSTALLATION........................137
REAR AXLE - 10 1/2 AA
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, 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 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 - 112 REAR AXLE - 10 1/2 AADR

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)

AXLE SHAFTS
REMOVAL
(1) Remove axle shaft flange bolts (Fig. 17).
(2) Slide axle shaft out of the axle tube.
(3) Remove axle shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use
Mopar Lock N' Seal or LoctiteT242 on cleaned
existing bolts.
(1) Clean axle flange and hub.
(2) Install new axle shaft gasket.
(3) Slide axle shaft into the axle tube.
(4) Install axle shaft flange bolts and tighten to
129 N´m ( 95 ft. lbs.).
PINION INSTALLER 8981
FLANGE PULLER 8992
BRIDGE 938
Fig. 17 AXLE FLANGE BOLTS
1 - AXLE FLANGE
2 - FLANGE BOLT
3 - 124 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

AXLE BEARINGS
REMOVAL
(1) Remove axle shaft flange bolts and remove axle
shaft.
(2) Remove retianer ring (Fig. 18) from the axle
shaft tube.
(3) Remove hub bearing nut locking key (Fig. 19).(4) Remove hub bearing nut with Socket 8954.
(5) Remove hub and bearings from the axle.
(6) Pry out hub bearing seal from the back of the
hub.
NOTE: The inner part of the seal may stay on the
axle tube (Fig. 20). This part must also be removed.
(7) Remove rear bearing.
(8) Remove hub bearing cups with a hammer and
drift.
INSTALLATION
(1) Install outer hub bearing cup with Installer
8961 and Handle C-4171.
(2) Install inner hub bearing cup with Installer
8962 and Handle C-4171.
(3) Pack bearings with the appropriate grease.
(4) Install rear bearing and installnewgrease
seal with Installer 8963 and Handle C-4171.
(5) Slide hub on the axle tube and install front
bearing into the hub.
(6) Install hub bearing nut with Socket 8954 and
tighten to 30 N´m (22 ft. lbs.) while rotating the hub
(Fig. 21).
(7) Back off nut about 30É and align next hub nut
key slot with axle tube key slot and install locking
key.
NOTE: End play should be 0.025-0.25 mm
(0.001-0.010 in.).
Fig. 18 RETAINER RING
1 - RETAINER RING
2 - LOCKING KEY
3 - BEARING NUT
Fig. 19 LOCKING KEY
1 - BEARING NUT
2 - LOCKING KEY
3 - AXLE TUBE
Fig. 20 INNER PART OF SEAL
1-PRYBAR
2 - AXLE TUBE
3 - REMAINING SEAL
DRREAR AXLE - 10 1/2 AA 3 - 125

(8)Install retainer ring with ring end in the key slot.
(9) Install new axle shaft gasket and install axle
shaft.
PINION SEAL
REMOVAL
(1) Remove axle shafts.
(2) Mark propeller shaft and pinion flange for
installation reference and remove shaft.
(3) Rotate pinion gear three or four times.
(4) Measure and record the amount of torque nec-
essary to rotate the pinion gear with an inch pound
torque wrench (Fig. 22).(5) Hold pinion flange with Flange Wrench 8979
(Fig. 23) and remove pinion flange nut and washer.
(6) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 24).
(7) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8896 and
Handle C-4171 (Fig. 25).
(2) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
Fig. 22 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 23 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
Fig. 24 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
3 - 126 REAR AXLE - 10 1/2 AADR
AXLE BEARINGS (Continued)

(5) Hold flange with Flange Wrench 8979 (Fig. 26)
and tighten pinion nut until pinion end play is taken
up.
(6) Rotate pinion several times to seat bearings.
(7) Measure pinion rotating torque with an inch
pound torque wrench and compare it to recorded
measurement.
(8) Tighten pinion nut in small increments, until
pinion rotating torque is 0.40-0.57 N´m (3-5 in. lbs.)
greater than recorded measurement.
(9) Rotate pinion several times then verify pinion
rotating torque again.
(10) Install axle shafts.
(11) Install propeller shaft with reference marks
aligned.
(12) Check and fill differential if necessary.
DIFFERENTIAL
REMOVAL
(1) Remove lubricant fill hole plug from the differ-
ential housing cover.
(2) Remove differential housing cover and drain
the lubricant from housing.
(3) Remove axle shafts.
(4) Remove adjuster lock bolts and adjuster locks
(Fig. 27).
(5) Mark bearing caps left and right for installa-
tion reference.
(6) Remove bearing cap bolts and remove bearing
caps.
(7) Loosen differential bearing adjusters (Fig. 28)
with Spanner Wrench 8883.
(8) Remove differential case from the housing.
(9) Remove bearing cups and tag them left and
right for installation reference.
Fig. 25 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 26 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 27 ADJUSTER LOCKS
1 - LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
DRREAR AXLE - 10 1/2 AA 3 - 127
PINION SEAL (Continued)