DODGE RAM 1999 Service Repair Manual

Fig. 1: Installing Axle Housing Spreader
Courtesy of Chrysler Corp.
6) Remove dial indicator. Pry differential case from axle
housing. If reusing bearing races for differential bearings, mark
bearing race location for reassembly reference. Bearing races must be
installed with original differential bearing.
7) If removing ring gear, place differential case in soft-jaw
vise. Remove and discard ring gear bolts. Using soft-face hammer, tap
ring gear from differential case.
8) Remove pinion nut and washer from pinion. Scribe reference
mark on pinion flange and pinion if components are to be reused.
9) Using Holder (C-3281) and appropriate flange remover,
remove pinion flange from pinion. Remove oil seal from axle housing.
10) Remove slinger (if equipped), pinion bearing and preload\
shim(s). Note thickness of preload shims for reassembly reference in
case shims become misplaced.
11) 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. Measure and record shim thickness for reassembly reference.
12) Remove rear (inner) bearing from pinion, using
appropriate puller. Remove differential bearings from differential
case. Remove preload shims from differential case. Identify preload
shim location. Record preload shim thickness for reassembly reference.
13) 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.
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 in 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 to retain roll pin in place. Remove differential case from
vise.
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.
3) Install ring gear on differential case. Use NEW ring gear
bolts. DO NOT reuse bolts. Tighten bolts evenly in alternating pattern
to specification. See TORQUE SPECIFICATIONS table. Proceed to INITIAL
DIFFERENTIAL BEARING PRELOAD.
Initial Differential Bearing Preload
1) Install dummy bearings on each side of differential case
where differential bearing fits. Use Dummy Bearing (D-345) for 216 FBI\
axle or (D-343) for 248 FBI axle.
2) Install differential case in axle housing. Install bearing
caps on axle housing. Ensure bearing caps are installed in original
location. Install bearing cap bolts.
3) Mount dial indicator on axle housing with stem against
back of ring gear. See Fig. 2. Pry between bearing cap and
differential case. Pry differential case to right as far as possible.
Zero dial indicator.
4) Pry differential case to the left as far as possible. Note
dial indicator reading. This reading is referred to as the
"differential case zero end play". Record differential case zero end
play reading.
5) Differential case zero end play measurement indicates
thickness of preload shims required to eliminate clearance between
differential bearings and bearing races.
6) Total thickness of preload shims will be determined during
ring gear backlash adjustment. Remove dial indicator, bearing caps and
differential case from axle housing. Proceed to PINION DEPTH
procedure.

Fig. 2: Measuring Differential Case End Play
Courtesy of Chrysler Corp.
Pinion Depth
1) Ring gear and pinion are a matched set. A gear matching
number is stamped on pinion face. This number must be same as number
on ring gear. A pinion depth variance marking is etched on pinion
face. See Fig. 3.
2) Etched marking (in thousandths of an inch) indicates
deviation from standard pinion depth setting. Standard pinion depth
setting is distance from center line of axle shaft to rear pinion
bearing shoulder area. See Fig. 3. Standard pinion depth setting
varies with axle model. See STANDARD PINION DEPTH SETTING table.
STANDARD PINION DEPTH SETTING









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Application In. (mm)\
216 FBI ............................................. 4.312 (109.52)\

248 FBI ............................................. 5.000 (127.00)\









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Fig. 3: Identifying Pinion Markings & Pinion Depth Measurement
Courtesy of Chrysler Corp.
3) If original pinion, ring gear and axle housing are being
used and pinion depth shims are being replaced, determine thickness of

original pinion depth shims. Replace shims with NEW shims of same
thickness.
4) If only pinion and ring gear are being replaced and
original axle housing is used, note pinion depth variance marking on
old pinion and replacement pinion.
5) Using etched markings and pinion depth shim adjustment
chart, determine amount to be added or subtracted from thickness of
original pinion depth shims. See Fig. 4. For example, if etched
marking is +4 on original pinion and -4 on replacement pinion,
thickness of pinion depth shims should be increased by .008" (.20 mm).\
NOTE: When using pinion depth shim adjustment chart, if result is a
negative (-) reading, subtract this amount from thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is positive (+), add this amount to thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is zero, this will be nominal standard pinion depth
setting and no shims are required. When using pinion depth
shim adjustment chart, thickness of original pinion depth
shim pack must be accurately determined. If original pinion
depth shim pack dimension cannot be accurately determined,
pinion depth gauge set must be used to properly determine
pinion depth setting. Pinion depth gauge set must also be
used if using replacement axle housing. Proceed to
DETERMINING PINION DEPTH USING PINION DEPTH GAUGE SET.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Fig. 4: Pinion Depth Shim Adjustment Chart
Courtesy of Chrysler Corp.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use Pinion Depth Gauge Set for all axle models. Place
master pinion block in pinion bore of axle housing. See Fig. 5.
Install discs on arbor. Install arbor in axle housing, with discs
positioned in differential bearing bores. See Fig. 5.
2) Install pinion height block on top of master pinion block,
against arbor. Place gauge block with dial indicator on lowest step of

pinion height block. Zero dial indicator with gauge block flat on
pinion height block.
3) Move gauge block so dial indicator stem contacts arbor.
Move gauge block back and forth (perpendicular to arbor) to get
highest reading. This reading is thickness of required pinion depth
shim pack.
4) To select correct shim, note etched markings on end of
pinion face. Etched marking (in thousandths of an inch) indicates
deviation from standard dimension.
5) When etched marking is negative (-), add this amount to
pinion depth shim pack to obtain correct shim thickness. When etched
marking is positive (+), subtract this amount from pinion depth shim
pack to obtain correct shim thickness. If etched marking is zero, no
change is required in pinion depth shim pack thickness.
6) Measure pinion depth shims separately using micrometer. If
slinger is used, slinger thickness must also be included in pinion
depth shim pack. Remove pinion depth gauge set components from axle
housing.
7) Place pinion depth shim pack in axle housing bore for rear
(inner) bearing race. Using appropriate bearing race installer, drive
rear (inner) bearing race into axle housing. Ensure bearing race is
fully seated.
8) Using bearing race installer, drive front (outer) bearing\
race into axle housing. Ensure bearing race is fully seated. Proceed
to PINION BEARING PRELOAD.
Fig. 5: Checking Pinion Depth
Courtesy of Chrysler Corp.
Pinion Bearing Preload
1) Install slinger on pinion (if equipped). Press rear

(inner) pinion bearing onto pinion until bearing is fully seated.
Install preload shims on pinion. Install pinion in axle housing.
Install front (outer) pinion bearing and slinger (if equipped).
Install pinion flange on pinion.
2) Using holder and Pinion Flange Installer (C-3716), press
pinion flange onto pinion. Install washer and used pinion nut. Tighten
pinion nut to specification. See TORQUE SPECIFICATIONS table.
3) Using INCH-lb. torque wrench, check torque required to
rotate pinion. This is pinion bearing preload. Ensure pinion bearing
preload is within specification. See AXLE ASSEMBLY SPECIFICATIONS.
4) If pinion bearing preload is not within specification,
adjust thickness of preload shims. Decrease shim thickness to increase
pinion bearing preload. Increase shim thickness to decrease pinion
bearing preload.
5) Remove nut and washer from pinion. Using holder and Pinion
Flange Remover (C-452), remove pinion flange from pinion. Ensure oil
seal surface in axle housing is clean.
6) Coat lip of oil seal with gear lube. Using appropriate oil
seal installer and handle, install oil seal.
7) Reinstall pinion flange, washer and NEW pinion nut. DO NOT
reuse pinion nut. Tighten pinion nut to specification. See TORQUE
SPECIFICATIONS table. Recheck pinion preload. Proceed to RING GEAR
BACKLASH.
NOTE: Before performing ring gear backlash, note differential case
zero end play obtained during initial differential bearing
preload. See INITIAL DIFFERENTIAL BEARING PRELOAD.
Ring Gear Backlash
1) Install dummy bearings on each side of differential case
where differential bearings fit. Use Dummy Bearing (D-345) for 216 FBI\
axle, or (D-343) for 248 FBI axle.
2) Install differential case in axle housing. Install bearing
caps on axle housing. Ensure bearing caps are installed in original
location. Install bearing cap bolts.
3) Mount dial indicator on axle housing with stem against
back of ring gear. Ensure pressure exists on stem of dial indicator.
Ensure ring gear and pinion are tightly meshed.
4) Pry between bearing cap and differential case. Pry
differential case as far to right as possible. Zero dial indicator.
5) Pry differential case to the left as far as possible, and
note reading on dial indicator. Repeat procedure several times to
ensure proper reading.
6) Measurement obtained determines preload shim thickness
required to eliminate ring gear backlash. Subtract reading obtained in
step 5) from differential case zero end play obtained during initial
differential bearing preload.
7) This is thickness of preload shims that must be installed
on ring gear side of differential case. These preload shims will be
referred to as the "ring gear backlash preload shims".
8) Remaining preload shims required to equal the differential
case zero end play will be referred as zero end play preload shims.
9) Remove dial indicator, bearing caps and differential case
from axle housing. Remove master bearings from differential case.
Install ring gear backlash preload shims on ring gear side of
differential case.
10) Install differential bearing on ring gear side of
differential case using appropriate bearing installer.
11) Install zero end play preload shims plus an additional .
015" (.38 mm) thick preload shim on differential case (opposite ring
gear side). Using bearing installer, install differential bearing on
differential case.
12) Install bearing races on differential bearings. If

reusing original differential bearings and bearing races, ensure
bearing races are installed in original locations.
13) Place axle housing spreader on axle housing so dowel pins
engage with locating holes. See Fig. 1. Use Axle Housing Spreader (W-
129-B). Install hold-down clamps. Tighten turnbuckle on axle housing
spreader finger tight.
14) Install pilot stud and dial indicator on axle housing.
See Fig. 1 . Position dial indicator so stem is resting against
opposite side of axle housing, with pressure on stem.
CAUTION: DO NOT spread axle housing more than .020" (.50 mm), or axle
housing may be damaged.
15) Adjust dial indicator to zero. Tighten turnbuckle enough
to spread axle housing for differential case removal while noting
reading on dial indicator. Dial indicator reading should not exceed .
020" (.50 mm).
16) Remove dial indicator. Install differential case and
bearing races in axle housing. Ensure differential bearings and races
are fully seated. Remove axle housing spreader.
17) Install bearing caps in original location. Install
bearing cap bolts, and tighten to specification. See TORQUE
SPECIFICATIONS table. Rotate differential case several times to seat
differential bearings.
18) Using dial indicator, check ring gear backlash. See
Fig. 6 . Ensure ring gear backlash is as specified. See AXLE ASSEMBLY
SPECIFICATIONS.
19) If ring gear backlash exceeds specification, move ring
gear toward pinion. If ring gear backlash is less than specification,
move ring gear away from pinion. To change ring gear backlash, move
preload shims from one side of differential case to other.
20) Check ring gear backlash every 90 degrees to check for
variation. Ring gear backlash variation should not exceed .002" (.05
mm). For example, if ring gear backlash is .005" (.15 mm) at minimum
point, ring gear backlash should not exceed .008" (.20 mm) anywhere on\
ring gear.
Final Inspection & Assembly
1) With ring gear backlash properly adjusted, check gear
tooth pattern contact. See GEAR TOOTH CONTACT PATTERNS article in
GENERAL INFORMATION.
2) When differential is complete and correctly adjusted,
install axle housing cover using NEW gasket (if equipped). If gasket
is not available, apply a 1/4" thick bead of silicone sealant on
inside of bolt holes and along sealing surfaces on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table. Fill differential with gear lube. See
LUBRICATION.
Fig. 6: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.

AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS








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Application Specification
Ring Gear Backlash ......................... .005-.008" (.13-.20 mm)\
Ring Gear Backlash Variation .................... ( 1) .002" (.05 mm)
Pinion Bearing Preload
New Bearings ........................... 15-35 INCH Lbs. (2-5 N.m)\
Used Bearings .......................... 10-20 INCH Lbs. (1-2 N.m)\
( 1) - Maximum variation from ring gear backlash measured at
minimum point on ring gear. If ring gear backlash is
.005" (.15 mm) at minimum point, ring gear backlash should
not exceed .007" (.18 mm) anywhere on ring gear.









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Applications Ft. Lbs. (N.m)\
ABS Sensor Bolt ................................................ ( 1)
Axle Nut ................................................. 175 (237)\
Ball Joint Stud Nut
216 FBI
Lower .................................................. 80 (109)\
Upper .................................................. 75 (102)\
248 FBI
Lower
1st Time .............................................. 35 (48)\
2nd Time .................................... 140-160 (190-217)\
Upper ................................................... 70 (95)\
Bearing Cap Bolt .......................................... 80 (109)\
Differential Cover Bolt .................................... 30 (41)\
Pinion Nut
216 FBI ........................................ 160-200 (217-271)\
248 FBI ........................................ 215-280 (292-380)\
Ring Gear Bolt
216 FBI ........................................... 70-90 (95-122)\
248 FBI ........................................ 120-140 (163-190)\
Shift Motor Mounting Bolt ...................................... ( 1)
Wheel Bearing Nut ........................................ 125 (170)\
( 1) - Tighten nuts to 96 INCH lbs. (11 N.m).









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DRIV E A XLE S - P O W ER -L O K

1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - Power-Lok
Ram Pickup
IDENTIFICATION
POWER-LOK DIFFERENTIAL APPLICATION








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Application Axle Ring Axle
Model Gear Size Ratio
Ram Pickup ........ Rear Axle ... 10.5" (266.7 mm) ..... 267 RBI\









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NOTE: For rear axles with limited-slip differentials, see TRAC-LOK
article.
DESCRIPTION & OPERATION
A Rear Beam-Design Iron (RBI) axle is an iron casting axle
and differential housing with axle shaft tubes extending from either
side. Tubes are pressed to form a one-piece full-floating axle
housing.
Power-Lok differential assembly is optional equipment. The
differential assembly is a limited-slip type differential. It is
similar in operation to a conventional type differential, except for 2
clutch packs located at the side gears in the differential case. See
Fig. 1 . Clutch packs provide differential action when required for
turning corners, and transmit equal torque to both wheels when driving
straight ahead.
AXLE RATIO & IDENTIFICATION
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
Ram Pickup ......................................... 3.54:1 & 4.10:1









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WARNING: Whenever rotating wheels, DO NOT use engine to rotate
individual wheels unless both rear wheels are off ground and
vehicle is securely supported.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1)








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Application Pts. (L)\
Ram Pickup ........................................... ( 2) 7.0 (3.3)