DODGE RAM 1999 Service Repair Manual

bearing preload is checked before disassembly, as previous
pinion bearing preload will be used during reassembly.
Removal
1) Raise and support vehicle. Scribe reference mark on drive
shaft-to-pinion flange on differential for reassembly reference.
Remove bolts and "U" joint straps at pinion flange on differential.
Disconnect drive shaft from differential.
2) Remove rear wheels and brake drums to prevent any drag
that may affect pinion bearing preload reading. Using INCH-lb. torque
wrench, measure amount of force required to rotate pinion. This is
pinion bearing preload. Record pinion bearing preload for reassembly
reference.
3) Using Holder (6719), hold pinion flange. Remove pinion nu\
t
and washer. Scribe reference mark on pinion flange-to-pinion for
reassembly reference. Using appropriate puller, remove pinion flange
from pinion. Remove oil seal from axle housing.
Installation
1) Ensure oil seal surface in axle housing is clean. Coat lip
of oil seal with gear lube. Install oil seal using appropriate seal
installer. Drive oil seal into axle housing until oil seal installer
contacts axle housing.
2) Install pinion flange on pinion with reference mark
aligned. Using appropriate pinion flange installer, install pinion
flange on pinion.
CAUTION: Washer must be installed on pinion with convex side of washer
facing outward (away from pinion).
3) Install washer on pinion with convex side of washer facing
outward (away from pinion). Install NEW pinion nut. Tighten pinion nut\
to 210 ft. lbs. (285 N.m). Rotate pinion several times to seat pinion
bearings.
CAUTION: DO NOT overtighten or loosen then retighten pinion nut when
adjusting pinion bearing preload. If pinion nut is over
tightened, collapsible spacer on pinion must be replaced. See
OVERHAUL.
4) Using INCH-lb. torque wrench, measure pinion bearing
preload. Tighten pinion nut in small increments until original pinion
bearing preload is obtained.
5) To install remaining components, reverse removal procedure
using NEW "U" joint straps and bolts. Ensure all reference marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Check lubricant level and add if necessary.
AXLE HOUSING ASSEMBLY
NOTE: It is not necessary to remove axle housing assembly, unless
axle housing is damaged. Differential carrier and components
can be serviced by removing differential assembly from axle
housing.
Removal
1) Raise and support vehicle. Block brake pedal in upward
position so brake pedal cannot be depressed, as brakelines must be
disconnected.
2) Remove rear wheels. DO NOT remove brake drums. Disconnect
brakelines at wheel cylinders. Cap brakelines to prevent fluid loss.
Disconnect axle housing vent hose.
3) Remove brake tee fitting bolt, and disengage brakelines

from axle housing clips. Disconnect electrical connector from brake
sensor mounted on top of axle housing (if equipped).
4) Disconnect parking brake cables. Scribe mark on drive
shaft and pinion flange for reassembly reference. Remove bolts and "U"
joint straps at pinion flange. Support drive shaft aside to prevent
damage to rear "U" joint.
5) Remove shock absorber from axle housing. Support axle
housing with floor jack. Remove "U" bolt nuts. Remove "U" bolts and
spring brackets. Lower axle housing from vehicle.
Installation
1) To install, reverse removal procedure. Ensure rear spring
center bolts align with holes in spring pads on axle housing.
2) Ensure reference mark on drive shaft and pinion flange are
aligned. Tighten bolt/nuts to proper specification. See TORQUE
SPECIFICATIONS. Bleed and adjust brakes.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential carrier and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
NOTE: Check pinion bearing preload, side play and then ring gear
runout, in this order, before disassembling differential
assembly.
Disassembly
1) Remove axle shafts. See AXLE SHAFT & BEARING under REMOVAL
& INSTALLATION. Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload. Record
pinion bearing preload for reassembly reference if front pinion
bearing will be replaced.
2) To check side play, place pry bar between differential
carrier and axle housing. Pry differential carrier to one side and
note if any side play exists. No side play should exist. If side play
exists, remove bolt and adjuster lock. See Fig. 1. Using Adjuster
Rotator (C-4164), tighten adjuster to eliminate side play.
3) To check ring gear runout, install dial indicator on axle
housing at 90 degree angle to ring gear, with stem resting against
flat side of ring gear, opposite gear teeth. Rotate ring gear, and
note ring gear runout.
NOTE: Ring gear must be removed from differential carrier before
checking differential carrier flange runout. Differential
carrier and bearings must be reinstalled in axle housing to
check differential carrier flange runout.
4) Mark ring gear and differential carrier at point of
maximum ring gear runout for reassembly reference. If ring gear runout
does not exceed .005" (.13 mm), differential carrier and ring gear are\
okay. If ring gear runout exceeds .005" (.13 mm), check differential
carrier flange runout once ring gear is removed.
5) Remove brake sensor from top of axle housing (if
equipped). Mark bearing caps and axle housing for reassembly
reference.
CAUTION: Mark all bearing races and adjusters in relation to their

respective differential bearings for reassembly reference.
6) Remove bolt and adjuster lock (if not previously removed)\
.
Loosen, but DO NOT remove, bearing cap bolts. Using Adjuster Rotator
(C-4164), unscrew adjusters from bearing caps. See Figs. 1 and 2.
Remove bolts, bearing caps, adjusters, and differential assembly.
7) Using Holder (C-3281), hold pinion flange. Remove pinion
nut and washer. Scribe reference mark on pinion flange-to-pinion for
reassembly reference. Using appropriate puller, remove pinion flange
from pinion. Remove oil seal for pinion from axle housing. Using soft
drift punch and hammer, drive pinion from axle housing.
NOTE: Front pinion bearing, bearing race, and collapsible spacer
must be replaced after removing pinion from axle housing.
8) Drive pinion bearing races from axle housing. Remove
pinion bearing from pinion. Remove shim(s) located behind pinion
bearing on pinion. Record shim thickness for reassembly reference.
CAUTION: DO NOT remove ring gear from differential carrier unless
components must be replaced or differential carrier flange
runout must be checked.
9) If removing ring gear (and exciter ring on RWAL brake
equipped models), mount differential carrier in soft-jaw vise. Remove
and discard left-hand thread ring gear bolts. Using soft-face hammer,
drive ring gear from differential carrier. Tap exciter ring from
differential carrier, if equipped.
10) If disassembling differential carrier, rotate side gears
and align pinion gears with opening in differential carrier. Remove
pinion gears and pinion gear thrust washers. See Fig. 1. Remove side
gears and side gear thrust washers.
11) If checking differential carrier flange runout, install
differential carrier, bearing races, bearing caps and adjusters in
axle housing. Ensure components are installed in original location.
Thread adjusters into bearing caps.
12) Tighten bearing cap bolts enough to just hold bearing
caps against axle housing. Using Adjuster Rotator (C-4164), tighten
adjuster so no side play exists. Side play can be checked by prying
differential carrier to one side.
13) Install dial indicator on axle housing with stem resting
against differential carrier flange. See Fig. 2. Rotate differential
carrier and note differential carrier flange runout. Replace
differential carrier if runout exceeds .003" (.08 mm).
14) Remove dial indicator, bearing caps, adjusters, bearing
races and differential carrier. Remove differential bearings from
differential carrier (if necessary).
15) Use appropriate puller and adapter (bearing splitter) to\
remove bearing from carrier. On models with Rear Wheel Anti-Lock
(RWAL) brakes, if removing exciter ring, use hammer and soft drift to
tap exciter ring from differential carrier.

Fig. 2: Checking Differential Carrier Flange Runout
Courtesy of Chrysler Corp.
Cleaning & Inspection
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, and replace as
matched set.
NOTE: Lubricate all bearings, bearing races, gears and thrust
washers with gear lube during reassembly.
Reassembly & Adjustments
1) Install side gear thrust washers on side gears. Install
side gears in differential carrier. Install pinion gear thrust washers
on pinion gears. Install pinion gears in differential carrier so gears
are positioned 180 degrees apart when meshed with side gears.
NOTE: If replacing side gears or side gear thrust washers, check
side gear clearance once differential carrier is installed in
axle housing. See FINAL INSPECTION & ASSEMBLY.
2) Rotate side gears until holes in pinion gears and thrust
washers align with pinion shaft hole in differential carrier. Install
pinion shaft. Ensure hole in pinion shaft is aligned with lock bolt

hole in differential carrier.
3) If ring gear and exciter ring (models with Rear Wheel
Anti-Lock brakes) were removed, slowly and evenly tap exciter ring
onto differential carrier. Ensure contact surface of ring gear and
differential carrier flange are clean and free of all nicks and burrs.
Remove any sharp areas from chamfer on inside diameter of ring gear.
4) Place ring gear into position on differential carrier.
Start 2 NEW ring gear bolts to align ring gear. Using brass drift and
hammer, alternately and evenly tap ring gear into position. Install
NEW ring gear bolts and tighten to specification. See TORQUE
SPECIFICATIONS.
NOTE: Use components from Pinion Gauge Set (C-3715-B) for 8 1/4"
ring gear, or (C-758-D6) for 9 1/4" ring gear) to complete
assembly. For proper component part number, see PINION GAUGE
SET COMPONENT APPLICATION table.
5) Install differential bearings on differential carrier (if
removed). Use appropriate bearing installer when installing
differential bearings. Go to PINION DEPTH.
PINION GAUGE SET COMPONENT APPLICATION









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Component 8 1/4" 9 1/4"
Ring Gear Ring Gear
Part No. Part No.
Arbor ........................... SP-6029 ................ SP-6018
Gauge Block ..................... SP-5383 ................ SP-6020
Nut ............................. SP-3193 ................. SP-533
Shaft ........................... SP-5385 ................. SP-526
Sleeve "A" ...................... SP-5382 ................ SP-1730
Sleeve "B" ..................... SP-3194-B .............. SP-535-A
Spacer "A" ...................... SP-6030 ................ SP-6017
Spacer "B" ...................... SP-6022 ................ SP-6022
Washer ........................... SP-534 ................. SP-534









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Pinion Depth
1) Using appropriate driver, install bearing races for pinion
bearings in axle housing (if removed). Assemble spacer "A" over shaft
followed by rear (pinion gear side) pinion bearing. See Fig. 3.
Install assembly into axle housing assembly.
2) Install sleeve "A" and front (pinion flange side) pinion
bearing on shaft. Install spacer "B", sleeve "B", washer and nut on
shaft. See Fig. 3. Using Holder (C-3281), hold sleeve "B" from
rotating and gradually tighten nut to seat pinion bearings.
NOTE: When tightening nut to seat pinion bearings, remove holder
and allow sleeve "B" to rotate several times during
tightening procedure to prevent damage to pinion bearings and
bearing cups.
3) Loosen nut. Lubricate pinion bearings with gear lube.
Retighten nut to 15-25 INCH lbs. (2-3 N.m). Rotate pinion several
times to fully seat pinion bearings.
4) Install gauge block and bolt on end of shaft. Using Allen
wrench, tighten bolt. Install arbor in axle housing. See Fig. 3.
Ensure arbor is centered in axle housing.
5) Place a piece of .002" (.05 mm) thick shim stock between
arbor and axle housing on each end of arbor. Install bearing caps over
arbor. Install and tighten bearing cap bolts to 120 INCH lbs. (14 N.
m). Using feeler gauge, check clearance between arbor and gauge block.

Fit must be snug but not tight.
6) To select correct shim, note etched markings on end of
face of pinion. Etched marking indicates (in thousandths of an inch)
deviation from standard dimension.
7) When etched marking is negative (-), add this amount to
feeler gauge thickness to obtain thickness of correct shim. When
etched marking is positive (+), subtract this amount to obtain
thickness of correct shim. If etched marking is zero, no change is
required.
8) Remove all pinion depth measuring components from axle
housing. Proceed to PINION BEARING PRELOAD.
Fig. 3: Identifying Pinion Depth Gauge Components & Measuring
Pinion Depth
Courtesy of Chrysler Corp.
Pinion Bearing Preload

1) Place selected shim on pinion. Press rear (pinion gear
side) pinion bearing on pinion. Lubricate pinion bearing with gear
lube.
CAUTION: DO NOT damage collapsible spacer when installing pinion
flange. If collapsible spacer is collapsed, install new
spacer.
2) Install pinion in axle housing. Install new collapsible
spacer and front (pinion flange side) pinion bearing. Using Pinion
Flange Installer (C-3718) and Holder (6719), install pinion flange o\
n
pinion to fully seat pinion bearings.
3) Remove pinion flange installer and pinion flange. Coat lip
of oil seal with gear lube. Install NEW oil seal. Drive NEW oil seal
into axle housing until oil seal installer contacts axle housing.
Install pinion flange, using pinion flange installer and holder.
CAUTION: Washer must be installed on pinion with convex side of washer
facing outward (away from pinion).
4) Install washer on pinion with convex side of washer facing
outward (away from pinion). Install NEW pinion nut. Using Holder
(6719), hold pinion flange. Tighten pinion nut only enough to remove
end play from pinion. Rotate pinion several times when tightening
pinion nut to fully seat pinion bearings.
5) Tighten pinion nut to 210 ft. lbs. (285 N.m). Remove
holder. Rotate pinion several times in both directions to fully seat
pinion bearings. Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload.
CAUTION: If original pinion bearings are installed, tighten pinion nut
until original pinion bearing preload is obtained. DO NOT
overtighten or loosen then retighten pinion nut when
adjusting pinion bearing preload. If pinion nut is
overtightened, replace collapsible spacer on pinion.
6) Continue tightening pinion nut in small increments until
correct bearing preload is obtained. See AXLE ASSEMBLY SPECIFICATIONS.
Go to RING GEAR BACKLASH & DIFFERENTIAL BEARING PRELOAD.
Ring Gear Backlash & Differential Bearing Preload
1) Lubricate differential bearings, bearing races and
adjusters with gear lube. Install differential carrier assembly,
bearing races and adjusters into axle housing.
2) Install bearing caps in original location. Install bolts
in bearing caps. Tighten upper bolts to 120 INCH lbs. (14 N.m).
Tighten lower bolts finger tight until bolt head is lightly seated
against bearing cap.
NOTE: To ensure bearing races are fully seated against differential
bearings, after rotating adjuster, rotate pinion back and
forth 5-10 times. This procedure must be performed anytime
adjusters are rotated.
3) Using Adjuster Rotator (C-4164), rotate each adjuster
inward until differential bearing free play is eliminated. Ensure
approximately .010" (.25 mm) ring gear backlash exists between ring
gear and pinion.
4) Install dial indicator on axle housing cover flange.
Position stem of dial indicator against drive side of tooth on ring
gear. Check ring gear backlash every 90 degrees to find point of
minimum ring gear backlash.
5) Mark ring gear at point of minimum ring gear backlash so

ring gear backlash will be checked with same teeth meshed. Rotate ring
gear to point of minimum ring gear backlash.
6) Loosen right adjuster (viewed from rear of axle housing)
and tighten left adjuster until ring gear backlash is .003-.004" (.08-
.10 mm) with each adjuster tightened to 120 INCH lbs. (14 N.m).
7) Rotate pinion back and forth 5-10 times to ensure proper
seating of differential bearings. Ensure ring gear backlash is still
as specified. Tighten bearing cap bolts to specification. See TORQUE
SPECIFICATIONS table.
8) Using adjuster rotator, tighten right adjuster to 75 ft.
lbs. (102 N.m). Rotate pinion back and forth 5-10 times to ensure
proper seating of differential bearings. Continue to tighten right
adjuster until torque remains constant at 75 ft. lbs. (102 N.m).
9) Recheck ring gear backlash at point of minimum ring gear
backlash. If ring gear backlash is not .005-.008" (.13-.20 mm),
increase torque on right adjuster, and seat differential bearings by
rotating pinion. Continue to tighten right adjuster until ring gear
backlash is correct.
10) Tighten left adjuster to 75 ft. lbs. (102 N.m). Rotate
pinion back and forth 5-10 times to ensure proper seating of
differential bearings. Continue to tighten left adjuster until torque
remains constant at 75 ft. lbs. (102 N.m).
11) Check ring gear backlash every 90 degrees to check ring
gear backlash variation. Ring gear backlash variation should not
exceed .003" (.08 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.
12) With adjustments completed, install adjuster locks.
Ensure teeth on adjuster lock engages with hole in adjuster. Install
and tighten adjuster lock bolt to specification. See TORQUE
SPECIFICATIONS table.
FINAL INSPECTION & ASSEMBLY
1) With pinion bearing preload and ring gear backlash
properly adjusted, check gear tooth pattern contact. See GEAR TOOTH
CONTACT PATTERNS article in GENERAL INFORMATION.
2) To check side gear clearance, install axle shafts into
axle housing and side gears. Install clip on end of axle shaft. Pull
axle shaft outward, ensuring clip fully seats in counterbore on side
gear.
NOTE: If replacing side gears or side gear thrust washers, check
side gear clearance with axle shaft installed in axle
housing. Check side gear clearance on both side gears.
3) Install equal thickness feeler gauges on each side of side
gear, next to hub of side gear. See Fig. 4. This is side gear
clearance.
Fig. 4: Checking Side Gear Clearance
Courtesy of Chrysler Corp.
4) If no side gear clearance exists, proceed to step 8). If

side gear clearance does not exceed .005" (.13 mm), determine if axle
shaft is contacting pinion shaft with feeler gauges installed. If axle
shaft is not contacting pinion shaft, side gear clearance is correct.
5) If side gear clearance exceeds .005" (.13 mm) and axle
shaft is not contacting pinion, record side gear clearance. Remove
pinion shaft, pinion gears, thrust washers, side gear and side gear
thrust washer. Measure thickness of side gear thrust washer.
6) Add thickness of side gear thrust washer to side gear
clearance measurement. This is required thickness of replacement side
gear thrust washer.
7) For example, if side gear clearance was .007" (.18 mm) an\
d
side gear thrust washer thickness is .033" (.84 mm), replacement side
gear thrust washer thickness is .040" (1.02 mm). Install replacement
side gear thrust washer and recheck side gear clearance.
8) If no side gear clearance exists, remove clip and axle
shaft. Remove pinion shaft, pinion gears, thrust washers, side gear
and side gear thrust washer. Measure and record thickness of side gear
thrust washer.
9) Reassemble side gear and components in differential
carrier. Install axle shaft in side gear. DO NOT install clip. Recheck
side gear clearance. If side gear clearance is now less than .012" (.
30 mm), add this measurement to thickness of side gear thrust washer
thickness. This is thickness of replacement side gear thrust washer.
10) If side gear clearance in step 9) is .012" (.30 mm) or
more, both side gears must be replaced and side gear clearance
rechecked. If side gear clearance is still .012" (.30 mm) or more with\
replacement side gears, replace differential carrier.
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS








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Application In. (mm)\
Maximum Differential Carrier Flange Runout .............. .003 (.08)\
Maximum Ring Gear Runout ................................ .005 (.13)\
Ring Gear Backlash ............................. .005-.008 (.13-.20)\
Ring Gear Backlash Variation ( 1) ........................ .003 (.08)
INCH Lbs. (N.m.)
Pinion Bearing Preload
New Bearings ......................................... 10-20 (1-2)\
Used Rear & New Front Bearing ............................. ( 2) 10
( 1) - This is amount of variation in ring gear backlash from reading
obtained at minimum point on ring gear. If ring gear backlash is
.005" (.13 mm) at minimum point, ring gear backlash should not
exceed .008" (.20 mm) anywhere on ring gear.
( 2) - Maximum increase over original pinion bearing preload before
disassembly.









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 35 (47)\
Bearing Cap Bolt ......................................... 100 (136)\
Brake Sensor ............................................... 18 (24)\

Center Carrier Bearing Bolt ................................ 50 (68)\
Pinion Nut (Minimum Torque) .............................. 210 (285\
)
Ring Gear Bolt (1)
Dakota
8 1/4" ................................................. 75 (102)\
9 1/4" ................................................. 115 (157)\
Ram Pickup ............................................... 70 (95)\
Ram Van/Wagon ........................................... 75 (102)\
Shock Absorber Nut ......................................... 60 (81)\
"U" Bolt Nut
8 1/4" Ring Gear
Dakota 2WD .............................................. 65 (88)\
Dakota 4WD ............................................ 110 (149)\
9 1/4" Ring Gears
1/2" X 20 Bolt Thread ................................... 65 (88)\
9/16" X 18 Bolt Thread ................................ 110 (149)\
"U" Joint Strap Bolt
Diesel Models ............................................ 25 (34)\
Gasoline Models .......................................... 14 (19)\
Wheel Lug Nut
Dakota .......................................... 85-110 (115-149)\
Ram Pickup
5-Lug .......................................... 80-110 (108-149)\
8-Lug (Single Wheel) .......................... 120-150 (163-203\
)
8-Lug (Dual Wheel) ............................ 130-160 (176-217\
)
Ram Van/Wagon
1/2" Stud
60-Degree Cone ............................... 80-110 (108-149)\
90-Degree Cone ............................... 85-115 (115-156)\
5/8" Stud
90-Degree Cone .............................. 175-225 (237-305)\
Flanged Nut ................................. 300-350 (407-474)\
INCH Lbs. (N.m)
Adjuster Lock Bolt ......................................... 90 (10)\
Pinion Shaft Lock Bolt ( 2) ................................. 96 (11)
( 1) - Left-hand threaded bolts.
( 2) - Apply Loctite to bolt threads.









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