lock DODGE RAM 1500 1998 2.G User Guide

SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
The shock absorber bushings do not require any
type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
base lubricants will deteriorate the bushing.
REMOVAL
REMOVAL - 4X2
(1) Raise and support vehicle.
(2) Support the lower control arm outboard end.
(3) Remove the upper shock absorber nut, retainer
and grommet.
(4) Remove the lower nuts and remove the shock
absorber.
REMOVAL - 4X4
(1) Raise and support the vehicle.
(2) Remove the tire and wheel assembly.
(3) Support the lower control arm outboard end.
(4) Remove the upper shock nut and with the insu-
lator and retainer (Fig. 27).
(5) Remove the lower shock bolt (Fig. 27).
(6) Remove the shock
INSTALLATION
INSTALLATION - 4X2
NOTE: Upper shock nut must be replaced or use
Mopar Lock 'N Seal or LoctiteT242 on existing nut.(1) Install the lower retainer and grommet on the
shock absorber stud. Insert the shock absorber
through the frame bracket hole.
(2) Install the lower nuts and tighten the nuts to
28 N´m (21 ft. lbs.).
(3) Install the upper grommet, retainer and new
nut or use Mopar Lock 'N Seal or Loctitet242 on
existing nut, on the shock absorber stud. Tighten nut
to 54 N´m (40 ft. lbs.).
(4) Remove the support from the lower control arm
outboard end.
(5) Lower the vehicle.
INSTALLATION - 4X4
(1) Install the upper part of the shock into the
frame bracket with the insulators and retainers (Fig.
27).
(2) Install the nut and Tighten to 54 N´m (40 ft.
lbs.).
(3) Install the lower part of the shock into the
lower control arm and Tighten the bolt to 135 N´m
(100 ft. lbs.) (Fig. 27).
(4) Remove the support from the lower control arm
outboard end.
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Remove the support and lower the vehicle.
STABILIZER BAR
DESCRIPTION
The bar extends across the front underside of the
chassis and connects to the frame crossmember. The
Fig. 27 SHOCK 4X4
1 - INSULATOR & RETAINER
2 - NUT
3 - SHOCK ABSORBER
4 - BOLT
2 - 24 FRONT - INDEPENDENT FRONT SUSPENSIONDR

INSTALLATION
INSTALLATION - 4X4
(1) Install the stabilizer link to the vehicle.
(2) Install the lower nut and Tighten to 102 N´m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
INSTALLATION - 4X2
(1) Install the stabilizer link to the vehicle (Fig.
29).
(2) Install the lower nut and Tighten to 102 N´m
(75 ft. lbs.).
(3) Install the retainers, grommets and upper nut
and Tighten to 38 N´m (27 ft. lbs.).
(4) Remove the support and lower the vehicle.
TORSION BAR
DESCRIPTION
The front of the bar connects to the back side of
the lower suspension arm. The rear end of the bar is
mounted in a anchor that rests in the frame cross-
member.
OPERATION
The torsion bars are used to control ride height
and ride quality. The vehicle height is adjusted
through an anchor adjustment bolt that increases or
decreases the wind up of the torsion bar. Increasing
or decreasing the bar angle changes the wind up of
the suspension arms.
REMOVAL
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Raise and support the vehicle with the front
suspension hanging.
(2) Remove the transfer case skid plate (Refer to
13 - FRAME & BUMPERS/FRAME/TRANSFER
CASE SKID PLATE - REMOVAL).
NOTE: Count and record the number of turns for
installation reference.
(3) Mark the adjustment bolt setting.
(4) Install Special Tool - 8686 to the anchor arm
and the cross member (Fig. 30).(5) Increase the tension on the anchor arm tool
until the load is removed from the adjustment bolt
and the adjuster nut (Fig. 30).
(6) Turn the adjustment bolt counterclockwise to
remove the bolt and the adjuster nut..
(7) Remove the Special Tool - 8686, allowing the
torsion bar to unload (Fig. 30).
(8) Remove torsion bar and anchor. Remove anchor
from torsion bar (Fig. 31).
(9) Remove all foreign material from torsion bar
mounting in anchor and suspension arm.
(10) Inspect adjustment bolt, bearing and swivel
for damage.
Fig. 30 LOADING/UNLOADING TORSION BAR
1 - SPECIAL TOOL ± 8686
2 - CROSSMEMBER
Fig. 31 TORSION BAR
1 - ANCHOR
2 - SWIVEL
3 - TORSION BAR
4 - LOWER CONTROL ARM
2 - 26 FRONT - INDEPENDENT FRONT SUSPENSIONDR
STABILIZER LINK (Continued)

INSTALLATION
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Insert torsion bar ends into anchor and suspen-
sion arm.
(2) Position the anchor in the frame crossmember.
(3) Install Special Tool - 8686 to the anchor and
the crossmember (Fig. 30).
(4) Increase the tension on the anchor in order to
load the torsion bar.
(5) Install the adjustment bolt and the adjuster
nut.
(6) Turn adjustment bolt clockwise the recorded
amount of turns.
(7) Remove tool - 8686 from the torsion bar cross-
member (Fig. 30).
(8) Install the transfer case skid plate (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION).
(9) Lower vehicle and adjust the front suspension
height (Refer to 2 - SUSPENSION/WHEEL ALIGN-
MENT - STANDARD PROCEDURE).
(10) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT
NOTE: If the ball joint is equipped with a lubrication
fitting, grease the joint then road test the vehicle
before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.(3) Mount a dial indicator solidly to the frame and
then zero the dial indicator.
(4) Position dial indicator plunger on the topside of
the upper ball joint (Fig. 32).
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the ball joint
(Fig. 32).
NOTE: Use care not to pry or tear the ball joint
boot, when checking the free play.
(5) Position a pry bar between the steering
knuckle and the upper control arm. Pry upwards on
the upper control arm (Fig. 32).
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the upper control arm since the upper ball joint is
integral to the arm (Refer to 2 - SUSPENSION/
FRONT/UPPER CONTROL ARM - REMOVAL).
(7) If the upper ball joint is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
Fig. 32 UPPER BALL JOINT PLAY
1 - DIAL INDICATOR
2 - UPPER CONTROL ARM
3-PRYBAR
4 - KNUCKLE
5 - BALL JOINT BOOT
DRFRONT - INDEPENDENT FRONT SUSPENSION 2 - 27
TORSION BAR (Continued)

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceNew Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set, Pinion Block 8177,
Arbor Discs 8541 and Dial Indicator C-3339 (Fig. 7).(1) Assemble Pinion Height Block 6739, Pinion
Block 8177 and rear pinion bearing onto Screw 6741
(Fig. 7).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through the
pinion bearing cups (Fig. 8).
(3) Install front pinion bearing and Cone-Nut 6740
onto the screw. Tighten cone-nut until Torque To
Rotate the screw is 2.0 N´m (18 in. lbs.) (Fig. 7).
(4) Place Arbor Discs 8541 on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 9).
Install differential bearing caps on arbor discs and
tighten cap bolts to specification.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
Fig. 7 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 8 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
DRFRONT AXLE - C205F 3 - 33
FRONT AXLE - C205F (Continued)

(6) Place Scooter Block/Dial Indicator in position
in the housing so dial probe and scooter block are
flush against the surface of the pinion height block.
Hold scooter block in place and zero the dial indica-
tor. Tighten dial indicator face lock screw.
(7) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 10). Slide the dial probe to the crest of the arbor
bar and record the highest reading.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
marked on the shaft of the pinion gear using the
opposite sign on the variance number. For example, if
the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cup and the housing. The proper shim thick-
ness can be determined using slip-fit Dummy Bear-
ings 8398 in place of the differential side bearings
and a Dial Indicator C-3339. Before measuring differ-
ential bearing preload and gear backlash, measure
pinion gear depth and prepare pinion for installation.Pinion gear depth is essential to establishing gear
backlash and tooth contact patterns. After measuring
shim thickness to take up differential side play,
install pinion and measure gear backlash shim thick-
ness. Overall shim thickness is the dial indicator
reading and preload specification added together. The
gear backlash measurement determines the shim
thickness used on the ring gear side of the differen-
tial case. Subtract gear backlash shim thickness from
overall shim thickness to determine shim thickness
for pinion gear side of the differential (Fig. 11).
Fig. 9 PINION GAUGE TOOLS
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 10 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 11 ADJUSTMENT SHIM
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
5 - COLLAPSIBLE SPACER
3 - 34 FRONT AXLE - C205FDR
FRONT AXLE - C205F (Continued)

REMOVER C-4660-A
SPREADER W-129-B
INSTALLER 5063
INSTALLER 6448
HOLDER 6719A
PINION DEPTH SET 6775
DUMMY SHIM 8107
ADAPTER PLATES 8142A
PINION BLOCK 8177
DRFRONT AXLE - C205F 3 - 41
FRONT AXLE - C205F (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove snap ring from the axle shaft.
(5) Remove axle with Remove 8420A Collar 8420-3
and Slide Hammer C-3752 (Fig. 27).
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Install axle shaft and engage shaft into side
gear. Push firmly on axle shaft to engage snap-ring.
(3) Check the differential fluid level and add fluid
if necessary.
(4) Install half shaft.
(5) Install skid plate, if necessary.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal with a small pry bar.
INSTALLATION
(1) Clean axle shaft bore clean.
(2) Install anewaxle shaft seal with Installer
8694 and Handle C-4171 (Fig. 28).(3) Lubricate seal lip with gear lubricant.
(4) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
(5) Install axle shaft O-ring.
(6) Install skid plate, if necessary.
(7) Install half shaft.
AXLE BEARINGS
REMOVAL
(1) Remove half shaft, axle shaft and seal.
Fig. 27 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 28 SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 29 BEARING REMOVER
1 - AXLE BEARING
2 - NUT
3 - REMOVER
DRFRONT AXLE - C205F 3 - 43

(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears (2) and remove
pinion gears (3) and thrust washers (1) (Fig. 40).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their original locations.
(1) Lubricate differential components with hypoid
gear lubricant.
(2) Install side gears and thrust washers into the
differentail case.
(3) Rotate pinion mate gears and thrust washers
into the differentail case.
(4) Install pinion gear mate shaft.
(5) Align hole in pinion gear mate shaft with hole
in the differential case.
(6) Install roll-pin (3) in the differential case with
a punch (1) and hammer (Fig. 41). Peen edge of roll-
pin hole in differential case in two places 180É apart.
(7) Install ring gear.
Fig. 39 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 40 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 41 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
DRFRONT AXLE - C205F 3 - 47
DIFFERENTIAL (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)

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move scooter
block till dial indicator crests the arbor, then record
the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 10).
(2) Loosen the differential bearing caps.
(3) 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.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the dif-
ferential bearings.
Fig. 8 GAUGE TOOLS IN HOUSING
1. PINION HEIGHT BLOCK
2. PINION BLOCK
3. ARBOR
4. ARBOR DISCS
Fig. 9 PINION DEPTH MEASUREMENT
1. DIAL INDICATOR
2. ARBOR
3. SCOOTER BLOCK
Fig. 10 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 60 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)