1999 DODGE RAM brake

pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembly
reference in case shims become misplaced.
12) Remove pinion and bearing from axle housing. Using
appropriate remover, remove front (outer) pinion bearing race from
axle housing. Remove rear (inner) pinion bearing race from axle
housing using remover. Remove pinion bearing depth shims from axle
housing. See Fig. 1. Measure and record shim thickness for reassembly
reference.
13) Remove rear (inner) bearing from pinion, using
appropriate puller. Remove differential bearings from differential
case. Remove preload shims from differential case. See Fig. 1.
Identify preload shim location. Record preload shim thickness for
reassembly reference.
14) Clamp differential case in soft-jaw vise. Remove roll pin
from differential case. Tap pinion shaft from differential case.
Remove pinion gears, pinion gear thrust washers, side gears and side
gear thrust washers from differential case.
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect components for wear. Inspect bearings and bearing races for
wear and pitting. Replace bearings and bearing races as a set. Inspect
ring gear and pinion teeth for wear and chipping. Replace ring gear
and pinion gear as matched set.
2) Check differential case for cracks or scoring of side
gears, thrust washers and pinion thrust faces. Check fit of side gears
to differential case and axle shaft splines. Examine shaft of pinion
shaft for scoring or excessive wear.
3) On axles with Rear Wheel Anti-Lock (RWAL) brakes, if
exciter ring is not removed from differential case, ensure exciter
ring fits tightly on differential case and is fully seated.
NOTE: Lubricate all bearings, bearing races, gears and thrust
washers with gear lube during reassembly.
Reassembly & Adjustments
1) Place differential case in soft-jaw vise. Install side
gears, side gear thrust washers, pinion gears and pinion gear thrust
washers into differential case.
2) Rotate side gears until holes in pinion gears and thrust
washers align with holes in differential case. Install pinion shaft.
Install roll pin in differential case. Stake edge of differential case
in 2 areas, 180 degrees apart, to retain roll pin in place. Remove
differential case from vise.
3) On rear axles with Rear Wheel Anti-Lock (RWAL) brakes,
align tab on exciter ring with slot on differential case if installing
exciter ring. Install ring gear on differential case. Install 2 NEW
ring gear bolts to maintain bolt hole alignment. Using press, press
exciter ring onto differential case using ring gear as a pilot.
4) Install ring gear on differential case (if not previously
installed). Install NEW ring gear bolts. Tighten bolts evenly in
alternating pattern to specification. See TORQUE SPECIFICATIONS table.
Proceed to INITIAL DIFFERENTIAL BEARING PRELOAD.
NOTE: Initial differential bearing preload must be performed to
determine thickness of preload shims in order to obtain zero
end play of differential case. Procedure must be performed
before installing pinion in axle housing.
Initial Differential Bearing Preload
1) Install master bearings on each side of differential case


DRIV E A XLE - 8 .2 5" & 9 .2 5" R IN G G EA R

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 8 1/4" & 9 1/4" Ring Gears
Dakota, Ram Pickup, Ram Van/Wagon
NOTE: For models using full-floating axles in which vehicle weight
is supported by axle housing tubes, see RBI FULL-FLOATING
AXLES article.
DESCRIPTION & OPERATION
Drive axle contains a solid semi-floating axle shaft splined
into the side gear. On semi-floating axle shafts, vehicle weight is
supported on axle shaft and bearing. Drive shaft rotates the pinion
which drives the ring gear. Power is transferred from ring gear
through side gears to the axle shafts (hypoid gear type).
On rear axles used in vehicles with Rear Wheel Anti-Lock
(RWAL) brakes, a brake sensor is mounted on top of axle housing, and
an exciter ring is mounted on the differential carrier. See Fig. 1.
Fig. 1: Exploded View Of Drive Axle
Courtesy of Chrysler Corp.
AXLE RATIO & IDENTIFICATION

NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS









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Application Ratio
8 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.90:1
9 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.92:1









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LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1)








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Application Pts. (L)\
8 1/4" Ring Gears .................................... ( 2) 4.4 (2.1)
9 1/4" Ring Gear ..................................... ( 2) 4.9 (2.3)
( 1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add 5 ounces of (148 ml) Trac-Loc additive.









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FLUID TYPE
Use SAE 80W-90 hypoid gear lubricant with MIL-L-2105-C and
API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & BEARING
CAUTION: When servicing differential, DO NOT rotate one axle shaft
unless both axles are installed into differential. Rotation
of one axle shaft without other in place may result in
misalignment of side gears in differential. This would
require difficult realignment of side gears before axle
shafts can be installed.
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Clean area around axle housing cover. Loosen axle housing cover bolts.
Drain lubricant from axle housing. Remove bolts and axle housing
cover. Rotate differential carrier for access to lock bolt. See Fig. 1
.
2) Remove lock bolt and pinion shaft from differential
carrier. See Fig. 1. Push axle shaft inward, toward center of vehicle.
Remove clip from groove in end of axle shaft. Remove axle shaft from

bearing preload is checked before disassembly, as previous
pinion bearing preload will be used during reassembly.
Removal
1) Raise and support vehicle. Scribe reference mark on drive
shaft-to-pinion flange on differential for reassembly reference.
Remove bolts and "U" joint straps at pinion flange on differential.
Disconnect drive shaft from differential.
2) Remove rear wheels and brake drums to prevent any drag
that may affect pinion bearing preload reading. Using INCH-lb. torque
wrench, measure amount of force required to rotate pinion. This is
pinion bearing preload. Record pinion bearing preload for reassembly
reference.
3) Using Holder (6719), hold pinion flange. Remove pinion nu\
t
and washer. Scribe reference mark on pinion flange-to-pinion for
reassembly reference. Using appropriate puller, remove pinion flange
from pinion. Remove oil seal from axle housing.
Installation
1) Ensure oil seal surface in axle housing is clean. Coat lip
of oil seal with gear lube. Install oil seal using appropriate seal
installer. Drive oil seal into axle housing until oil seal installer
contacts axle housing.
2) Install pinion flange on pinion with reference mark
aligned. Using appropriate pinion flange installer, install pinion
flange on pinion.
CAUTION: Washer must be installed on pinion with convex side of washer
facing outward (away from pinion).
3) Install washer on pinion with convex side of washer facing
outward (away from pinion). Install NEW pinion nut. Tighten pinion nut\
to 210 ft. lbs. (285 N.m). Rotate pinion several times to seat pinion
bearings.
CAUTION: DO NOT overtighten or loosen then retighten pinion nut when
adjusting pinion bearing preload. If pinion nut is over
tightened, collapsible spacer on pinion must be replaced. See
OVERHAUL.
4) Using INCH-lb. torque wrench, measure pinion bearing
preload. Tighten pinion nut in small increments until original pinion
bearing preload is obtained.
5) To install remaining components, reverse removal procedure
using NEW "U" joint straps and bolts. Ensure all reference marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Check lubricant level and add if necessary.
AXLE HOUSING ASSEMBLY
NOTE: It is not necessary to remove axle housing assembly, unless
axle housing is damaged. Differential carrier and components
can be serviced by removing differential assembly from axle
housing.
Removal
1) Raise and support vehicle. Block brake pedal in upward
position so brake pedal cannot be depressed, as brakelines must be
disconnected.
2) Remove rear wheels. DO NOT remove brake drums. Disconnect
brakelines at wheel cylinders. Cap brakelines to prevent fluid loss.
Disconnect axle housing vent hose.
3) Remove brake tee fitting bolt, and disengage brakelines

from axle housing clips. Disconnect electrical connector from brake
sensor mounted on top of axle housing (if equipped).
4) Disconnect parking brake cables. Scribe mark on drive
shaft and pinion flange for reassembly reference. Remove bolts and "U"
joint straps at pinion flange. Support drive shaft aside to prevent
damage to rear "U" joint.
5) Remove shock absorber from axle housing. Support axle
housing with floor jack. Remove "U" bolt nuts. Remove "U" bolts and
spring brackets. Lower axle housing from vehicle.
Installation
1) To install, reverse removal procedure. Ensure rear spring
center bolts align with holes in spring pads on axle housing.
2) Ensure reference mark on drive shaft and pinion flange are
aligned. Tighten bolt/nuts to proper specification. See TORQUE
SPECIFICATIONS. Bleed and adjust brakes.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential carrier and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
NOTE: Check pinion bearing preload, side play and then ring gear
runout, in this order, before disassembling differential
assembly.
Disassembly
1) Remove axle shafts. See AXLE SHAFT & BEARING under REMOVAL
& INSTALLATION. Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload. Record
pinion bearing preload for reassembly reference if front pinion
bearing will be replaced.
2) To check side play, place pry bar between differential
carrier and axle housing. Pry differential carrier to one side and
note if any side play exists. No side play should exist. If side play
exists, remove bolt and adjuster lock. See Fig. 1. Using Adjuster
Rotator (C-4164), tighten adjuster to eliminate side play.
3) To check ring gear runout, install dial indicator on axle
housing at 90 degree angle to ring gear, with stem resting against
flat side of ring gear, opposite gear teeth. Rotate ring gear, and
note ring gear runout.
NOTE: Ring gear must be removed from differential carrier before
checking differential carrier flange runout. Differential
carrier and bearings must be reinstalled in axle housing to
check differential carrier flange runout.
4) Mark ring gear and differential carrier at point of
maximum ring gear runout for reassembly reference. If ring gear runout
does not exceed .005" (.13 mm), differential carrier and ring gear are\
okay. If ring gear runout exceeds .005" (.13 mm), check differential
carrier flange runout once ring gear is removed.
5) Remove brake sensor from top of axle housing (if
equipped). Mark bearing caps and axle housing for reassembly
reference.
CAUTION: Mark all bearing races and adjusters in relation to their

respective differential bearings for reassembly reference.
6) Remove bolt and adjuster lock (if not previously removed)\
.
Loosen, but DO NOT remove, bearing cap bolts. Using Adjuster Rotator
(C-4164), unscrew adjusters from bearing caps. See Figs. 1 and 2.
Remove bolts, bearing caps, adjusters, and differential assembly.
7) Using Holder (C-3281), hold pinion flange. Remove pinion
nut and washer. Scribe reference mark on pinion flange-to-pinion for
reassembly reference. Using appropriate puller, remove pinion flange
from pinion. Remove oil seal for pinion from axle housing. Using soft
drift punch and hammer, drive pinion from axle housing.
NOTE: Front pinion bearing, bearing race, and collapsible spacer
must be replaced after removing pinion from axle housing.
8) Drive pinion bearing races from axle housing. Remove
pinion bearing from pinion. Remove shim(s) located behind pinion
bearing on pinion. Record shim thickness for reassembly reference.
CAUTION: DO NOT remove ring gear from differential carrier unless
components must be replaced or differential carrier flange
runout must be checked.
9) If removing ring gear (and exciter ring on RWAL brake
equipped models), mount differential carrier in soft-jaw vise. Remove
and discard left-hand thread ring gear bolts. Using soft-face hammer,
drive ring gear from differential carrier. Tap exciter ring from
differential carrier, if equipped.
10) If disassembling differential carrier, rotate side gears
and align pinion gears with opening in differential carrier. Remove
pinion gears and pinion gear thrust washers. See Fig. 1. Remove side
gears and side gear thrust washers.
11) If checking differential carrier flange runout, install
differential carrier, bearing races, bearing caps and adjusters in
axle housing. Ensure components are installed in original location.
Thread adjusters into bearing caps.
12) Tighten bearing cap bolts enough to just hold bearing
caps against axle housing. Using Adjuster Rotator (C-4164), tighten
adjuster so no side play exists. Side play can be checked by prying
differential carrier to one side.
13) Install dial indicator on axle housing with stem resting
against differential carrier flange. See Fig. 2. Rotate differential
carrier and note differential carrier flange runout. Replace
differential carrier if runout exceeds .003" (.08 mm).
14) Remove dial indicator, bearing caps, adjusters, bearing
races and differential carrier. Remove differential bearings from
differential carrier (if necessary).
15) Use appropriate puller and adapter (bearing splitter) to\
remove bearing from carrier. On models with Rear Wheel Anti-Lock
(RWAL) brakes, if removing exciter ring, use hammer and soft drift to
tap exciter ring from differential carrier.

hole in differential carrier.
3) If ring gear and exciter ring (models with Rear Wheel
Anti-Lock brakes) were removed, slowly and evenly tap exciter ring
onto differential carrier. Ensure contact surface of ring gear and
differential carrier flange are clean and free of all nicks and burrs.
Remove any sharp areas from chamfer on inside diameter of ring gear.
4) Place ring gear into position on differential carrier.
Start 2 NEW ring gear bolts to align ring gear. Using brass drift and
hammer, alternately and evenly tap ring gear into position. Install
NEW ring gear bolts and tighten to specification. See TORQUE
SPECIFICATIONS.
NOTE: Use components from Pinion Gauge Set (C-3715-B) for 8 1/4"
ring gear, or (C-758-D6) for 9 1/4" ring gear) to complete
assembly. For proper component part number, see PINION GAUGE
SET COMPONENT APPLICATION table.
5) Install differential bearings on differential carrier (if
removed). Use appropriate bearing installer when installing
differential bearings. Go to PINION DEPTH.
PINION GAUGE SET COMPONENT APPLICATION









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Component 8 1/4" 9 1/4"
Ring Gear Ring Gear
Part No. Part No.
Arbor ........................... SP-6029 ................ SP-6018
Gauge Block ..................... SP-5383 ................ SP-6020
Nut ............................. SP-3193 ................. SP-533
Shaft ........................... SP-5385 ................. SP-526
Sleeve "A" ...................... SP-5382 ................ SP-1730
Sleeve "B" ..................... SP-3194-B .............. SP-535-A
Spacer "A" ...................... SP-6030 ................ SP-6017
Spacer "B" ...................... SP-6022 ................ SP-6022
Washer ........................... SP-534 ................. SP-534









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Pinion Depth
1) Using appropriate driver, install bearing races for pinion
bearings in axle housing (if removed). Assemble spacer "A" over shaft
followed by rear (pinion gear side) pinion bearing. See Fig. 3.
Install assembly into axle housing assembly.
2) Install sleeve "A" and front (pinion flange side) pinion
bearing on shaft. Install spacer "B", sleeve "B", washer and nut on
shaft. See Fig. 3. Using Holder (C-3281), hold sleeve "B" from
rotating and gradually tighten nut to seat pinion bearings.
NOTE: When tightening nut to seat pinion bearings, remove holder
and allow sleeve "B" to rotate several times during
tightening procedure to prevent damage to pinion bearings and
bearing cups.
3) Loosen nut. Lubricate pinion bearings with gear lube.
Retighten nut to 15-25 INCH lbs. (2-3 N.m). Rotate pinion several
times to fully seat pinion bearings.
4) Install gauge block and bolt on end of shaft. Using Allen
wrench, tighten bolt. Install arbor in axle housing. See Fig. 3.
Ensure arbor is centered in axle housing.
5) Place a piece of .002" (.05 mm) thick shim stock between
arbor and axle housing on each end of arbor. Install bearing caps over
arbor. Install and tighten bearing cap bolts to 120 INCH lbs. (14 N.
m). Using feeler gauge, check clearance between arbor and gauge block.

side gear clearance does not exceed .005" (.13 mm), determine if axle
shaft is contacting pinion shaft with feeler gauges installed. If axle
shaft is not contacting pinion shaft, side gear clearance is correct.
5) If side gear clearance exceeds .005" (.13 mm) and axle
shaft is not contacting pinion, record side gear clearance. Remove
pinion shaft, pinion gears, thrust washers, side gear and side gear
thrust washer. Measure thickness of side gear thrust washer.
6) Add thickness of side gear thrust washer to side gear
clearance measurement. This is required thickness of replacement side
gear thrust washer.
7) For example, if side gear clearance was .007" (.18 mm) an\
d
side gear thrust washer thickness is .033" (.84 mm), replacement side
gear thrust washer thickness is .040" (1.02 mm). Install replacement
side gear thrust washer and recheck side gear clearance.
8) If no side gear clearance exists, remove clip and axle
shaft. Remove pinion shaft, pinion gears, thrust washers, side gear
and side gear thrust washer. Measure and record thickness of side gear
thrust washer.
9) Reassemble side gear and components in differential
carrier. Install axle shaft in side gear. DO NOT install clip. Recheck
side gear clearance. If side gear clearance is now less than .012" (.
30 mm), add this measurement to thickness of side gear thrust washer
thickness. This is thickness of replacement side gear thrust washer.
10) If side gear clearance in step 9) is .012" (.30 mm) or
more, both side gears must be replaced and side gear clearance
rechecked. If side gear clearance is still .012" (.30 mm) or more with\
replacement side gears, replace differential carrier.
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS








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Application In. (mm)\
Maximum Differential Carrier Flange Runout .............. .003 (.08)\
Maximum Ring Gear Runout ................................ .005 (.13)\
Ring Gear Backlash ............................. .005-.008 (.13-.20)\
Ring Gear Backlash Variation ( 1) ........................ .003 (.08)
INCH Lbs. (N.m.)
Pinion Bearing Preload
New Bearings ......................................... 10-20 (1-2)\
Used Rear & New Front Bearing ............................. ( 2) 10
( 1) - This is amount of variation in ring gear backlash from reading
obtained at minimum point on ring gear. If ring gear backlash is
.005" (.13 mm) at minimum point, ring gear backlash should not
exceed .008" (.20 mm) anywhere on ring gear.
( 2) - Maximum increase over original pinion bearing preload before
disassembly.









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 35 (47)\
Bearing Cap Bolt ......................................... 100 (136)\
Brake Sensor ............................................... 18 (24)\