DODGE RAM 1999 Service Repair Manual

Fig. 4: Identifying Pinion Markings & Pinion Depth Measurement
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. 4.
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. 4. 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)\
248 RBI ............................................. 5.000 (127.00)\
267 RBI ............................................. 5.375 (136.52)\
286 RBI ............................................. 5.812 (147.62)\









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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. 5. 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 determining shim thickness, 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 procedure.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use pinion depth gauge set for all axle models. Place
master pinion block into pinion bore of axle housing. See Fig. 6.
Install discs on arbor. Install arbor in axle housing with discs
positioned in differential bearing bores. See Fig. 6.
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.
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-3718) for 246\
and 267 models, Installer (D-191) for 286 models, 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
table.
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.
Fig. 5: Pinion Depth Shim Adjustment Chart
Courtesy of Chrysler Corp.

Fig. 6: Checking Pinion Depth
Courtesy of Chrysler Corp.
6) Coat lip of oil seal with gear lube. Using appropriate oil
seal installer and handle, install oil seal.

NOTE: Before performing ring gear backlash, note differential case
zero end play obtained during initial differential bearing
preload. See INITIAL DIFFERENTIAL BEARING PRELOAD procedure.
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 procedure.
Ring Gear Backlash
1) Install master bearings on each side of differential case
where the differential bearing fits. Use Dummy Bearing (D-343) for 248\
and 267 RBI axles, and (D-346) for 286 RBI 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 onto 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 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 "ring gear backlash preload shims".
8) Remaining preload shims required to equal 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 onto ring gear side of
differential case.
10) Install differential bearing onto 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 onto differential case (opposite rin\
g
gear side). Using bearing installer, install differential bearing onto
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. 2. Use Axle Housing Spreader (W-
129-B). Install hold-down clamps. Finger tighten turnbuckle on axle
housing spreader.
14) Install pilot stud and dial indicator on axle housing.
See Fig. 2 . 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 and
tighten bearing cap bolts 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. 7. 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 the
minimum point, ring gear backlash should not exceed .007" (.18 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 proper specification. See TORQUE
SPECIFICATIONS. Fill differential with gear lube. See LUBRICATION.
Fig. 7: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.
AXLE ASSEMBLY SPECIFICATIONS

AXLE ASSEMBLY SPECIFICATIONS








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Application Specification
Ring Gear Backlash
248/267 .................................. .004-.009" (.10-.23 mm)\
286 ...................................... .005-.009" (.13-.23 mm)\
Ring Gear Backlash Variation .................... (1) .002" (.05 mm)
INCH Lbs. (N.m)
Pinion Bearing Preload
New Bearings
Ram Pickup & Wagon .............................. 15-35 (1.7-4.0)\
Ram Van ......................................... 20-40 (2.3-4.5)\
Used Bearings (All Models) ....................... 10-20 (1.1-2.3\
)
( 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
248 & 267 RBI ................................................ ( 1)
286 RBI .................................................. 18 (24)\
Axle Housing Cover Bolt
Ram Pickup ............................................... 30 (41)\
Ram Van/Wagon ............................................ 35 (47)\
Axle-To-Hub Bolt .......................................... 90 (122)\
Bearing Cap Bolt .......................................... 80 (109)\
Fill Hole Plug ............................................. 25 (34)\
Hub Adjustment Nut ............................... 120-140 (163-190)\
Pinion Nut
248 & 267 RBI .................................. 215-330 (292-447)\
286 RBI ........................................ 440-500 (597-678)\
Ring Gear Bolt
248 & 267 RBI .................................. 120-140 (163-190)\
286 RBI ........................................ 200-240 (271-325)\
Shock Absorber Nuts ........................................ 60 (81)\
"U" Joint Strap Bolt ....................................... 14 (19)\
( 1) - Tighten nuts to 97 INCH lbs. (11 N.m).









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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

axle housing.
CAUTION: DO NOT damage axle shaft bearing in axle housing when
removing axle shaft.
3) Inspect axle shaft-to-axle shaft bearing contact area for
damage. Replace axle shaft and axle shaft bearing if axle shaft is
damaged. Using small pry bar, pry oil seal from axle housing (if
necessary).
4) If replacing axle shaft bearing, use appropriate bearing
puller and slide hammer to remove axle shaft bearing. Rotate threaded
shaft on bearing puller to remove axle shaft bearing.
CAUTION: Ensure axle shaft bearing surface in axle housing is free of
burrs and clean before installing axle shaft bearing.
Installation
1) Using appropriate bearing/seal installer, install bearing.
Ensure axle shaft bearing is bottomed against shoulder in bore.
Install NEW oil seal in axle housing until installer contacts axle
housing.
2) Lubricate axle shaft bearing and oil seal lip with gear
lube. Install axle shaft so splines engage with splines on side gear.
DO NOT damage oil sea when installing axle shaft.
3) Install clip on end of axle shaft. Pull axle shaft
outward, ensuring clip fully seats in counterbore on side gear.
Install pinion shaft ensuring pinion shaft hole aligns with lock bolt
hole.
4) Apply Loctite to CLEAN threads on lock bolt. Install and
tighten lock bolt to specification. See TORQUE SPECIFICATIONS. Ensure
axle housing and axle housing cover sealing surfaces are clean.
5) Apply a 1/4" thick bead of silicone sealant on inside of
bolt holes and along sealing surfaces on axle housing cover. Install
axle housing cover, axle identification tag, and retaining bolts.
Tighten bolts in crisscross pattern to proper specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Fill differential. See LUBRICATION.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer case are in Neutral. Scribe mark on drive shaft-to-pinion
flange for reassembly reference.
2) On 2-piece drive shafts, scribe center carrier bearing-to-
frame bracket reference line for reassembly reference. On all drive
shafts, remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft(s).
CAUTION: "U" joint straps and bolts must be replaced. DO NOT reuse.
Installation
To install, reverse removal procedure using NEW "U" joint
straps and bolts. Ensure all reference marks are aligned. Tighten
bolts to specification. See TORQUE SPECIFICATIONS.
PINION FLANGE & OIL SEAL
CAUTION: Following procedure must be used to retain proper pinion
bearing preload. Failure to follow procedure may result in
premature axle assembly or component failure. Ensure pinion