torque DODGE RAM 1500 1998 2.G Repair Manual

DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 41).
(6) If rotating torque is less than 41 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Holding Fixture 8136 in vise and set
differential case on fixture (Fig. 42).
(2) Remove pinion gear mate shaft screw.
(3) Remove pinion gear mate shaft.
Fig. 40 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 41 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 42 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
DRREAR AXLE - 9 1/4 3 - 101
DIFFERENTIAL-TRAC-LOK (Continued)

(4) Lubricate and install disc, that is not threaded
from Trac-LoktTool Kit 8139 into the lower side gear
(Fig. 43).
(5) Install threaded disc from Trac-LoktTool Kit
8139 into top side gear. Thread forcing screw from
Trac-LoktTool Kit C-4487 through top disc until it
comes in contact with lower disc.
(6) Position a small screw driver in slot of top disc
(Fig. 44) to prevent disc from turning.
(7) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress Belleville springs in clutch
packs (Fig. 45).
(8) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 46).
(9) Insert turning bar from tool kit into pinion
mate shaft hole in the case (Fig. 47).
Fig. 43 ADAPTER DISC
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
Fig. 44 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED DISC
Fig. 45 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
3 - 102 REAR AXLE-91/4DR
DIFFERENTIAL-TRAC-LOK (Continued)

(8) Install anewcollapsible spacer on the pinion
shaft (Fig. 67).
(9) Lubricate rear pinion bearing and install pin-
ion gear into the housing.
(10) Install companion flange with Installer
C-3718 and Holder 6719.
(11) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(12) 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.
(13) Install companion flange washer and anew
nut on the pinion and tighten the nut until there is
zero bearing end-play.
(14) With a torque wrench tighten the nut to 285
N´m (210 ft. lbs.) (Fig. 68).
CAUTION: Never loosen pinion nut to decrease pin-
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(15) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until the desired rotating torque is
achieved. Measure pinion rotating torque frequently
to avoid over crushing the collapsible spacer.(16) Check pinion rotating torque with an inch
pound torque wrench (Fig. 69). The pinion rotating
torque should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 1.7 to 5 N´m (15 to 35 in. lbs.).
Fig. 67 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
Fig. 68 PINION NUT
1 - DIFFERENTIAL HOUSING
2 - HOLDER
3 - TORQUE WRENCH
Fig. 69 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - TORQUE WRENCH
3 - 110 REAR AXLE-91/4DR
PINION GEAR/RING GEAR/TONE RING (Continued)

(17) Position exciter ring on differential case. With
a brass drift, slowly and evenly tap the exciter ring
into position.
(18) Position ring gear on the differential case and
start two ring gear bolts. This will provide case-to-
ring gear bolt hole alignment.
(19) Invert the differential case in the vise.
(20) Installnewring gear bolts and alternately
tighten to 156 N´m (115 ft. lbs.) (Fig. 70).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(21) Install differential in housing and verify gear
mesh, backlash and contact pattern.
(22) Install axle shafts.
(23) Install differential cover and fill with gear
lubricant.
(24) Install propeller shaft with reference marks
aligned.
Fig. 70 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
DRREAR AXLE - 9 1/4 3 - 111
PINION GEAR/RING GEAR/TONE RING (Continued)

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)

INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.
(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install all brake components.
(5) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(6) Install the wheels and tires.
(7) Fill differential to specifications.
(8) Remove lift from axle and lower the vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets. Compensation for pinion depth variance is
achieved with a select shim. The shim is located
between the rear pinion bearing and the 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. 3).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8899 and rear pinion bearing onto Screw 6741
(Fig. 3).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 4).
(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.) (Fig.
3).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 5).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 165 N´m (122 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
(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.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 6). Move the
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.
Fig. 3 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. 4 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 116 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

(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 def-
erential bearings.
(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 9).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern correct (Fig. 10). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
11). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
Fig. 9 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 10 CORRECT CONTACT PATTERN
Fig. 11 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 118 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.10
Ring Gear Diameter 266 mm (10.5 in.)
Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.)
Pinion Bearing Preload - New Bearings 1.69-2.82 N´m (15-25 in. lbs.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload + Diff Case Bearing Preload -
New Bearings3.4-5.6 N´m (30-50 in. lbs.)
Pinion Bearing Preload + Diff Case Bearing Preload -
Original Bearings2.8-5.1 N´m (25-45 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fill Hole Plug 32 24 -
Differential Cover Bolts 40 30 -
Bearing Cap Bolts 165 122 -
Ring Gear Bolts 237 175 -
Axle Flange Bolts 129 95 -
Adjuster Lock Bolt 25 18 -
SPECIAL TOOLS
PULLER C-293-PA
DIAL INDICATOR SET C-3339
HANDLE C-4171
3 - 120 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

(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)