DODGE RAM 1500 1998 2.G Workshop Manual

(6) Install Extractor Rod 6310 with Extractor Foot
6310-9 through the receiver and the axle seal (Fig.
27).
(7) Install Extractor Plate 6310-2 and Nut 6310-7
on the extractor rod.
(8) Tighten nut on the extractor rod (Fig. 28) and
pull the seal out and into the receiver.INSTALLATION
(1) Install axle seal on Installer Cups 8885-2 and
position cups with seals into the housing.
NOTE: Seal are installed with the axle guide facing
outward.
(2) Install Turnbuckle 8885-1 (Fig. 29) into the
installer cups and expand the turnbuckle until the
seal bottom out in the housing.
(3) Install differential into the axle housing.
(4) Install axle shaft and hub bearings
PINION SEAL
REMOVAL
(1) Mark the propeller shaft and pinion flange for
installation reference.
(2) Remove propeller shaft.
(3) Remove hub bearings and axle shafts.
(4) Rotate pinion gear three or four times.
(5) Measure and record the torque necessary to
rotate (Fig. 30) the pinion gear with an inch pound
torque wrench.
Fig. 27 SEAL RECEIVER
1 - RECEIVER
2 - EXTRACTOR FOOT
Fig. 28 SEAL EXTRACTOR
1 - EXTRACTOR ROD
2 - EXTRACTOR NUT
Fig. 29 AXLE SEAL INSTALLER
1 - INSTALLER CUP
2 - INSTALLER TURNBUCKLE
3 - INSTALLER CUP
3 - 70 FRONT AXLE - 9 1/4 AADR
AXLE SHAFT SEALS (Continued)

(6) Hold pinion flange with Flange Wrench 8979
(Fig. 31) and remove pinion flange nut and washer.
(7) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 32).
(8) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8882 and
Handle C-4171 (Fig. 33).
(2) Apply a light coat of teflon thread sealant to
the pinion flange splines.(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
(5) Hold flange with Flange Wrench 8979 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. Tighten pinion nut in small incre-
ments, until pinion rotating torque is 0.40-0.57 N´m
(3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shafts and hub bearings.
(10) Install propeller shaft with reference marks
aligned.
Fig. 30 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 31 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 32 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 33 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
DRFRONT AXLE - 9 1/4 AA 3 - 71
PINION SEAL (Continued)

DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover and drain
lubricant from the housing.
(2) Remove hub bearings and axle shafts.
(3) Remove adjuster lock bolts and adjuster locks
(Fig. 34).
(4) Mark bearing caps left and right for installa-
tion reference.
(5) Remove bearing cap bolts and remove bearing
caps.
(6) Loosen differential bearing adjusters (Fig. 35)
with Spanner Wrench 8883.
(7) Remove differential case from the housing.
(8) Remove bearing cups and tag them left and
right for installation reference.
DISASSEMBLY
(1) Remove pinion shaft lock bolt.
(2) Remove pinion shaft (Fig. 36).
Fig. 34 ADJUSTERS AND LOCKS
1 - ADJUSTER LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
Fig. 35 ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
Fig. 36 PINION SHAFT
1 - PINION SHAFT
2 - PUNCH
3 - PINION GEAR
4 - SIDE GEAR
3 - 72 FRONT AXLE - 9 1/4 AADR

(3) Rotate differential pinion gears to differential
window and remove pinion gears and thrust washers
(Fig. 37).
(4) Remove differential side gears and thrust
washers (Fig. 38).
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their orignial locations.(1) Lubricate all differential components with axle
lubricant.
(2) Install differential side gears and thrust wash-
ers (Fig. 39).
(3) Rotate the one pinion gear with thrust washer
into the differential case (Fig. 40). Then rotate the
other pinion gear with thrust washer into the differ-
ential case.
Fig. 37 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - PINION GEAR
3 - THRUST GEAR
Fig. 38 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 39 SIDE GEARS
1 - DIFFERENTIAL WINDOW
2 - SIDE GEAR
Fig. 40 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEARS
3 - PINION GEAR
DRFRONT AXLE - 9 1/4 AA 3 - 73
DIFFERENTIAL (Continued)

(4) Align hole in the pinion gears with hole in the
differential case.
(5) Install pinion shaft.
(6) Installnewpinion shaft lock bolt and tighten
to 52 N´m (38 ft. lbs.).
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
(4) Install bearing caps and bolts (Fig. 41). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 85 N´m (63 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 42).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts and hub bearings.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
Fig. 41 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTERFig. 42 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 74 FRONT AXLE - 9 1/4 AADR
DIFFERENTIAL (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)

(7) Drive ring gear from differential case with a
soft hammer (Fig. 45).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 46) and remove pinion flange nut and washer.(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 47).
(10) Remove pinion gear from housing with Pinion
Driver 8976 and a hammer (Fig. 48).
NOTE: Thread drive on shaft until it bottoms out.
Fig. 45 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 46 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 47 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 48 PINION DRIVER
1 - PINION SHAFT
2 - PINION DRIVER
3 - 76 FRONT AXLE - 9 1/4 AADR
PINION GEAR/RING GEAR (Continued)

(11) Remove pinion seal with a slide hammer or
pry bar.
(12) Remove and discard front pinion bearing
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove collapsible spacer from the pinion
shaft.
(14) Remove rear pinion bearing with Puller
C-293-PA and Adapters 8879 (Fig. 49).
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the
housing with a punch and hammer and discard.
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the
housing with a punch and hammer, if bearing is
replaced.INSTALLATION
(1) Install front pinion bearing cup (Fig. 50) with
Installer D-146 and Handle C-4171.
(2) Install rear pinion bearing cup (Fig. 51) with
Installer 8886 and Handle C-4171, if bearing is
replaced.
Fig. 49 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
Fig. 50 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 51 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
DRFRONT AXLE - 9 1/4 AA 3 - 77
PINION GEAR/RING GEAR (Continued)

(3) Install pinion depth shim (Fig. 52) on the pin-
ion gear shaft.
(4) Install rear pinion bearing (Fig. 53) with
Installer C-3095-A and a press.(5) Installnewcollapsible spacer (Fig. 54).
(6) Lubricate pinion and bearings.
(7) Install pinion into the housing and place front
pinion bearing onto the pinion shaft. Draw the pinion
shaft into the front bearing with Installer 8982 (Fig.
55).
Fig. 52 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 53 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 54 COLAPSIBLE SPACER
1 - COLAPSIBLE SPACER
2 - PINION GEAR
3 - REAR PINION BEARING
Fig. 55 PINION GEAR INSTALLER
1 - INSTALLER
2 - DIFFERENTIAL HOUSING
3 - 78 FRONT AXLE - 9 1/4 AADR
PINION GEAR/RING GEAR (Continued)

(8) Installnewpinion seal (Fig. 56) with Installer
8882 and Handle C-4171.
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange
onto the pinion shaft, until a few threads are show-
ing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
and tighten pinion nut until end play is taken up.
(13) Rotate pinion several times to seat bearings.
(14) Measure pinion rotating torque with an inch
pound torque wrench (Fig. 57). Tighten pinion nut in
small increments until pinion rotating torque is:
²New Pinion Bearings:1.7-2.8 N´m (15-25 in.
lbs.)
²Original Pinion Bearings:1.1-2.2 N´m (10-20
in. lbs.)
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start twonewring gear bolts.
(17) Install the rest of thenewring gear bolts and
tighten them alternately to seat the ring gear.(18) Torque ring gear bolts to 140 N´m (103 ft.
lbs.).
(19) Install differential in housing.
(20) Measure final rotating torque with an inch
pound torque wrench. The final pinion rotating
torque plus differential case bearing preload is:
²New Bearings:3.4-5.6 N´m (30-50 in. lbs.)
²Original Bearings:2.8-5.1 N´m (25-45 in. lbs.)
(21) Install axle shafts.
(22) Verify ring gear backlash and gear contact
pattern.
(23) Install the propeller shaft with the reference
marks aligned.
(24) Install differential cover with gasket and
tighten to 40 N´m (30 ft. lbs.).
(25) Fill differential with fluid and tighten fill plug
to 32 N´m (24 ft. lbs.).
Fig. 56 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 57 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
DRFRONT AXLE - 9 1/4 AA 3 - 79
PINION GEAR/RING GEAR (Continued)