DODGE TRUCK 1993 Service Repair Manual

2
- 88
FRONT
SUSPENSION
AND
AXLE

•

TORQUE WRENCH SPECIAL TOOL
C-3281

RH418A

Fig.
61 Rotating
Pinion
Gear Ml

REMOVE SHIMS
BEARING PRELOAD
SHIM
PACK

PINION
LOCATING
SHIM
PACK

DIFFERENTIAL
BEARING
SHIM PACKS
RY660

Fig.
62
Shim
Locations
(18) Install a new yoke nut and tighten to 339-366
N-m (250-270 ft. lbs.) torque.

PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH
TOOL
SET
C-758-D6
The alternate measurement and adjustment proce­
dure involves using Pinion Depth Measurement Gauge Set C-758-D6 (Fig. 65). (1) Install the pinion rear bearing cup (Fig. 66)
with Installer D-lll and Handle C-4171.
Ensure the cup is correctly seated. (2) Install the pinion front bearing cup with In­
staller C-4203 and Handle C-4171 (Fig. 67). Assemble C-758-D6 Tool Set as described (Fig.

68);
SPECIAL
TOOL

C-452
J9102-31

Fig.
63
Pinion
Yoke
Removal

SPECIAL
TOOL C4735
SP-5184 C-3719-A
DIFFERENTIAL
HOUSING

J9203-56

Fig.
64
Pinion
Seal
Installation
SPECIAL
TOOL
SET C-758-D6

J9203-67

Fig.
65
Pinion
Adjustment Tools

•
.
C-4171 J9203-65
Fig.
66
Pinion
Rear Bearing Cup
Installation
BEARING
CUP DRIVER

INSTALLATION
TOOL
C-4203
HANDLE

Fig.
67
Pinion
Front Bearing Cup
Installation
•
Position Spacer (SP-5814 for Model 60) over Shaft
(SP-526)

•
Position pinion rear bearing on shaft

•
Position tools (with bearing) in the housing

•
Install pinion front bearing

•
Install Sleeve
(SP-535-A),
Washer (SP-534) and
Nut
(SP-533).
(3) Prevent compression sleeve tool from turning
with Wrench C-3281. Tighten the nut to seat the pin­ ion bearings in the housing (Fig. 68). Allow the
sleeve to turn several times during the tightening to
prevent brinelling the bearing cups or the bearings.
Depth shim(s) are positioned between the pin­
ion gear rear bearing and pinion gear to provide
the separation distance. The required thickness
FRONT SUSPENSION
AND
AXLE
2 - 69

Fig.
68 Seating
Pinion
Bearings
of the depth shim(s) is determined according to
the following information.
(4) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri­ cant. Re-tighten the compression nut tool to 1 to 3
Nnn (15 to 25 in. lbs.) torque. Rotate the pinion gear several complete revolutions to align the bearing
rollers.
(5) Install Gauge Block SP-5260 at the end of SP-

526.
Install Cap Screw (SP-536) and tighten with
Wrench
SP-531.

(6) Position Crossbore Arbor (SP-5183) in the
dif­

ferential housing.
Center the arbor in cradles so equal space exists at
both ends. Position the bearing caps on the arbor
tool. Install the bolts. Tighten the cap bolts to 14 Nnn (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 69). The depth shim(s)
fit must be snug but not tight (drag friction of a
feeler gauge blade).
SPACER

BEARING CAP ARBOR
J9203-53
Fig.
69 Depth
Shim(s)
Selection

SPECIAL
TOOL

2
- 70
FRONT
SUSPENSION
AND
AXLE

• Depth shims are available in O.OOl-ineh incre­
ments from 0.020 inch to 0.038 inch. (8) Note the etched number on the face of the drive
pinion gear (e.g., -0, -1, -2, +1, +2, etc.). The num­
bers represent thousands-of-an-inch deviation from
the standard. If the number is - (negative), add that
value to the required thickness of the depth shim(s).
If the number is + (positive), subtract that value
from the thickness of the depth shim(s). If the num­
ber is 0, no change is necessary.
(9) Remove the tools from the differential housing.
(10) Remove the rear bearing cup from housing
(Fig. 70) with Remover D-162 and Handle C-4171.
HAMMER
DRIVER
HANDLE
PRESS
DRIVE

PINION
GEAR SHAFT

REAR
BEARING' INSTALLATION

TOOL
DRIVE

PINION
GEAR OIL

SUNGER

J9302-68

Fig.
71
Pinion
Rear Bearing
Installation
SPECIAL
TOOL

C-3718
DIFFERENTIAL
HOUSING

J9203-58

Fig.
70 Rear Bearing Cup
Removal
(11) Position depth shims in housing rear bearing
cup bore.
(12) Install the pinion rear bearing cup (Fig. 66)
with Installer D-lll and Handle C-4171. Ensure the cup is correctly seated. (13) If the depth of mesh has been followed accord­
ing to the instructions above, good gear teeth contact should exist.
(14) Install the rear bearing (and slinger if used)
on the pinion gear with Installer C-3095-A until
completely seated (Fig. 71).
(15) Install pinion in housing bore.
(16) Assemble preload shims onto pinion and in­
stall the pinion gear in housing. (17) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer C-3718 and Wrench C-3281 (Fig. 72).
(18) Tighten the yoke nut to 339-366 N-m (250-270
ft. lbs.) torque.
SPECIAL

TOOL

C-3281

J9103-21

Fig.
72
Pinion
Yoke
Installation
(19) Check bearing preload torque with an inch
pound torque wrench (Fig. 73). The torque necessary to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.) • New Bearings — 2 to 5 N»m (20 to 40 in. lbs.) If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.
74);

• Increase the preload torque, decrease the shim
thickness

•

FRONT
SUSPENSION
AND
AXLE
2 - 71

TORQUE
WRENCH
SPECIAL
TOOL

G3281

RH418A

Fig.
73 Rotating
Pinion
Gear
• Decrease the preload torque, increase the shim
thickness

BEARING
PRELOAD

SHIM PACK
PINION
LOCATING
SHIM PACK
DIFFERENTIAL BEARING SHIM PACKS
RY660

Fig.
74
Shim
Locations
(20) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 75).
(21) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 76) with
Installer C-3719-A and Handle C-4735
(22) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 77).
(23) Install a new yoke nut and tighten to 339-366
N*m (250-270 ft. lbs.) torque.
SPECIAL
TOOL

C-452
J9102-31

Fig.
75
Pinion
Yoke
Removal

SPECIAL
TOOL
C-4735

SPECIAL
TOOL C-3719-A DIFFERENTIAL
HOUSING

J9203-56

Fig.
76
Pinion
Seal
Installation
RING
GEAR BACKLASH
ADJUSTMENT

(1) Place Master Differential Bearing D-343
(D-117) on the case hubs (Fig. 78).
(2) Install a pilot stud at the right side of housing.
Attach Dial Indicator C-3339 to the pilot stud. Load indicator plunger against the back of the ring gear (Fig. 78). Ensure ring and pinion gear teeth are
tightly meshed. Zero the indicator.
(3) Insert a small pry bar between the bearing cap
and right side of differential case. Pry the case as far
as possible to left side (Fig. 78). Zero the dial indica­
tor pointer.
(4) Repeat the measurement several times to check
consistency. Record the travel distance.
The measurement above shows shim thickness
necessary to eliminate ring gear backlash. Sub-

2
- 72
FRONT
SUSPENSION
AND
AXLE

•

SPECIAL
DIFFERENTIAL
TOOL
HOUSING

J9103-21

Fig.
77
Pinion
Yoke
Installation
Fig.
78
Ring Gear Backlash Measurement
tract this thickness
from
case zero end-play shim thickness.
The
shims must
be
placed
at the

ring gear side between
the
case
and
bearing. (5) Remove indicator
and
pilot stud.

(6)
Remove
the
differential case from housing.
(7) Remove
the
master bearing tools from
the dif­

ferential case hubs. (8) Position
the
backlash shims (with determined
thickness)
on
case
hub
(ring gear side). Install bear­
ing
on the hub
with Installer C-4025-A
and
Handle
C-4171
(Fig. 79).

Fig.
79
Differential Bearing
Installation

(9) Position
the
remaining zero end-play shims
on

hub
at
opposite side
of
case. Include
an
additional 0.015-in (0.38-mm) thick shim
on
this
hub.
This will
provide
the
required differential bearing preload
torque.
(10) Install bearing
on hub
with Installer
C-4025-A
and
Handle C-4171
(Fig. 79).
(11) Install
new
axle shaft
oil
seals
in
differential
housing with Installer D-195. Apply lubricant
to lip
of seals.
(12) Match each bearing
cup
with bearing (origi­

nal).
Install
the
cups
on the
bearings. (13) Position Spreader
D-167
with
the
tool dowel
pins seated
in the
locating holes
(Fig. 80).
Install
the

holddown clamps
and
tighten
the
tool turnbuckle fin­ ger-tight. (14) Install
a
pilot stud
at the
left side
of the dif­

ferential housing. Attach Dial Indicator
to
housing
pilot stud. Load
the
indicator plunger against
the op­

posite side
of the
housing
(Fig. 80) and
zero
the
indi­ cator.

CAUTION:
Do not
spread
over
the
specified
dis­
tance.
If the
housing
is
over-separated,
it
could
he
distorted
or
damaged.

(15) Separate
the
housing enough
to
install
the

case
in the
housing. Separate housing
a
maximum

•

FRONT
SUSPENSION
AND
AXLE
2 - 73

SPECIAL TOOL

.MODEL
44-W-129-A
MODEL
60 - D-167
DIAL

INDICATOR

J9202-114
TOOL

C-3339
Fig.
80
Differential
Housing
Separation
distance
of 0.38 mm
(0.015
in)
with
the
spreader
tool. Measure
the
distance with
the
dial indicator
(Fig.
80).
(16) Remove
the
dial indicator.
(17) Install case
in the
housing. Ensure
the
differ­
ential bearings
are
fully seated. Remove
the
spreader.
(18) Observe
the
assembly reference marks
and po­

sition
the
bearing caps
at
their original locations (Fig.
81).
Tighten
the
bearing
cap
bolts
to
95-122
Nnn (70-90
ft. lbs.)
torque.

Fig.
81
Differential
Bearing
Cap
Reference Letters (19) Rotate
the
assembly several revolutions
to

seat
the
bearings. Measure backlash
at
three equally
spaced locations with
a
dial indicator
(Fig. 82).
The ring gear backlash must
be
within 0.004
-

0.009 inch
(0.10 - 0.23 mm). It
cannot vary more
than 0.002 inch
(0.05 mm)
between
the
points checked.
(20) Excessive backlash
is
corrected
by
moving
the

ring gear teeth closer
to the
pinion gear teeth.
Insuf­

ficient backlash
is
corrected
by
moving
the
ring gear
Fig.
82
Ring
Gear
Backlash
Measurement
away from
the
pinion gear. Backlash correction
is ac­

complished
by
transferring shims from
one
side
to

the other.
If
the
mesh
and
backlash steps have been followed
in
the
procedures above, good gear teeth contact pat­
terns should exist.
RING GEAR TEETH CONTACT PATTERN
ANALYSIS
The ring gear teeth contact patterns will show
if

the pinion gear depth shim(s) have
the
correct thick­
ness.
It
will also show
if the
ring gear backlash
has

been adjusted correctly.
The
backlash must
be
main­
tained within
the
specified limits until
the
correct
teeth contact patterns
are
obtained.
(1) Apply
a
thin coat
of
hydrated ferric oxide,
to

the ring gear teeth. (2) Rotate
the
ring gear
one
complete revolution
in

both directions while
a
load
is
being applied. Insert
a
pry
bar
between
the
differential housing
and the
case
flange. This action will produce distinct contact pat­ terns
on
both
the
drive side
and
coast side
of the
ring gear teeth.
(3) Note patterns
in
compound. Refer
to (Fig. 83)

for interpretation
of
contact patterns
and
adjust
ac­
cordingly.
(4) Install
the
axle shafts. Refer
to
Axle Shaft
In­

stallation within this group.
(5) Install
the
housing cover. Refill
the
differential
with lubricant. Refer
to
Axle Shaft Installation.

2
- 74
FRONT SUSPENSION AND AXLE

DRIVE
SIDE
OF RING

GEAR
TEETH
HEEL

TOE
COAST
SIDE
OF RING

GEAR
TEETH TOE

HEEL
DESIRABLE
CONTACT PATTERN.
PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH.
PATTERN SHOULD BE CENTERED
ON

THE COAST
SIDE
OF TOOTH, BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE
SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP
OF

THE TOOTH.
RING GEAR
BACKLASH
CORRECT.

THINNER
PINION GEAR DEPTH
SHIM REQUIRED.
RING GEAR
BACKLASH
CORRECT.

THICKER
PINION GEAR DEPTH SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT
DECREASE
RING

GEAR
BACKLASH.

PINION GEAR DEPTH SHIM

CORRECT
INCREASE
RING

GEAR
BACKLASH.

Fig.
83 Gear Teeth Contact Patterns
J9003-24

FRONT
SUSPENSION
AND
AXLE
2 - 75

SPECIFICATIONS

MODEL
60
FRONT
AXLE

Axle Type........
Semi-floating,
hypoid

Application
D-TRK Ring Gear
Diameter
9.75
in.
(24.76 cm)
Lubricants
MOPAR
Gear
Lubricant
or
equivalent
SAE
75W-90,

API
Grade
GL-5,
MIL-L-2105C

Locking
Hubs Manual
type

Lubricant Capacity
6.5
pts. (3.1L)
Axle Model Dana
M60F

Axle Ratio.........
3.54
Tol
4.10
4.56
Track... 65.7
in.
GAWR....................
4500
lbs.

TORQUE
SPECIFICATIONS
Differential
Bearing
Preload Shim 0.015
in.
0.38
mm

Differential
Side Gear-to-Case Clearance..
0.000-0.007
in.
0.00-0.18
mm

Ring
Gear Backlash 0.005-0,008
in.
0.12-0.20 mm
Drive Pinion Gearshaft Bearing Break-Away Preload Torque
Original
Bearings....
10-20
in. lbs. l-2N®m Replacement Bearings. 20-40
in.
lbs. 2-5 N®m
Drive Pinion Gear Depth Select shims Standard Setting.... 3.125
in.
79.37 mm

Side
Gear Clearance (max.) 0.006
in.
0.15
mm

Case
Runout (max.) 0.006
in.
0.15
mm
J9202-107

FRONT
SUSPENSION
COMPONENTS-
2WD
FRONT
SUSPENSION
COMPONENTS-
4WD

FRONT
SUSPENSION
COMPONENTS
%
WHEEL
DRIVE
FRONT
SUSPENSION
COMPONENTS

4
WHEEL
DRIVE

DESCRIPTION
TOROUE

Brake Rotor
Dust
Shield
Jounce Bumper to Bracket.... Lower
Suspension
Arm Pivot.
Lower Ball Stud
Nut
(11/16-18 Bolt)...............
Lower Ball Stud
Nut

(3/4-16 Bolt).....

Shock
Absorber Upper Nut..
Shock
Absorber Lower Bolt
..

Stabilizer Bar Retainer
Bolts
.

Stabilizer Bar Link Nut
Steering Arm to Knuckle 5/8-18 Bolt/Nut
.............

Steering Arm to Knuckle 3/4-16 Bolt/Nut . 20 N-m (180 in.
lbs.

....
41
N-m
(30
ft. lbs.
305
N-m (225
ft. lbs.

183
N-m (135
ft. lbs.

237 N-m (175
ft. lbs.

....
34
N-m
(25 ft.
lbs. .
23
N-m
(200
in. lbs.
.
23
N-m
(200
in. lbs.
. 11 N-m
(100
in. lbs.
Strut/Jounce Bumper to
Suspension
Arm Bolt/Nut.
Strut
Front
Nut Upper Ball Stud
Nut
290 N-m (215
ft. lbs.

330 N-m (225
ft.
lbs.

.. 129 N-m (95
ft.
lbs.
....
68
N-m
(50
ft.
lbs.
142
N-m
(105
ft.
lbs.

J9202-108
DESCRIPTION

TORQUE

Jounce Bumper to Bracket
....
Stabilizer Bar Retainer
Bolts..

Stabilizer Bar Link Nut

Shock
Absorber/Jounce Bracket to Frame

Shock
Absorber (Standard) Upper and Lower Nut

Shock
Absorber (Air Adjust) Upper Nut

Shock
Absorber (Air Adjust) Lower Nut

Spring
U-bolt/Stud Nuts (Model
44) ...

Spring
Front Pivot Nut (Model
44)

Spring
Rear Shackle
Nut
(Model
44)

Spring
U-bolt/Stud Nuts (Model
60)

Spring
Front
Pivot Nut (Model
60)

Spring
Rear Shackle Nut (Model
60)
...
41
N-m (30
ft.
lbs.)

23
N-m (200 in.
lbs.)
11
N-m
(100
in.
lbs.)

.. 101 N-m (75
ft.
lbs.)

.... 75 N-m (55
ft.
lbs.)

.... 75 N-m (55
ft.
lbs.)

271 N-m
(200
ft.
lbs.)

.. 115 N-m (85
ft.
lbs.)

135
N-m (100
ft.
lbs.)

.... 81 N-m
(60
ft.
lbs.)

..
129
N-m
(95
ft.
lbs.)

135
N-m (100
ft.
lbs.)

,.
108
N-m
(80
ft.
lbs.)
J9202-109

2
- 76
FRONT
SUSPENSION
AND
AXLE

MODEL
44 AXLE

MODEL
60 AXLE

FRONT
AXLE MODEL 44
FRONT
AXLE MODEL #0

DESCRIPTION
TORQUE

Bearing Cap
Bolts
95 to 122 N-m (70 to 90 ft. lbs.)
Brake/Spindle
Splash
Shield 34 to 41 N-m
(25 to 35 ft. lbs.)

Differential
Cover
Bolts
47 N-m (35 ft. lbs.)

Fill
Hole Plug 34 N-m (25 ft. lbs.)
Lower Ball Stud Nut 108 N-m (80 ft. lbs.)
Pinion Yoke Nut 271 to 298 N-m (200 to 220 ft. lbs.)
Shift Motor
Housing
Bolts 14 N-m (10 ft. lbs.) Spindle
Wheel
Bearing
Outer
Lock Nut...... 68 N-m (50 ft. lbs.)
Steering Knuckle Arm Nuts 122 N-m (90 ft. lbs.)

Ring
Gear
Bolts
61 to 81 N-m (45 to 60 ft. lbs.)
Upper Ball Stud Nut 136 N-m (100 ft. lbs.)
Upper Yoke Sleeve 54 N-m (40 ft. lbs.)
J9202-110
DESCRIPTION

TORQUE

Bearing Cap Bolts
Brake
Splash
Shield/Spindle.

Differential
Cover Bolts

Fill
Hole Plug
Lower King Pin Cap Screws...
Pinion Yoke Nut.
Spindle
Wheel
Bearing
Outer
Lock Nut

Ring
Gear
Bolts
(Grade 8)

Ring
Gear
Bolts
(Grade 9)
Upper King Pin Cap
Upper King Pin 95 to 122 N-m
(70 to 90 ft. lbs.)
68 to 81 N-m
(50 to 60 ft. lbs.)
47 N-m (35 ft. lbs.) 34 N-m (25 ft. lbs.) 95 to 122 N-m
(70 to 90 ft. lbs.) 339 to 366 N-m
(250 to 270 ft. lbs.)
.... 217 to 278 N-m (160 to 205 ft. lbs.)

136tol63N-m

(100 to 120 ft. lbs.)
..... 169 to 183 N-m (125 to 135 ft. lbs.)
96 to 122 N-m
(70 to 90 ft. lbs.)
668 to 813 N-m
(500 to 600 ft. lbs.)

J9202-111

•

REAR
SUSPENSION
AND
AXLE
3 - 1
CONTENTS

page

8
3/8 and 9 1/4
AXLE
11
GENERAL
INFORMATION
1
MODEL
60 and 70
AXLES
29

POWER-LOK DIFFERENTIAL
55

REAR
SUSPENSION—2WD
and
4WD VEHICLES
3
page

SERVICE
DIAGNOSIS
6

SPECIFICATIONS
27

SURE-GRIP
DIFFERENTIAL SERVICE
28

TORQUE SPECIFICATIONS
59

TRAC-LOK DIFFERENTIAL
51

GENERAL INFORMATION

SUSPENSION
Ram Truck rear suspensions
are
comprised
of;

• Drive axle
• Leaf springs
• Dual-action shock absorbers
• Jounce bumpers (used
to
limit
the
travel
of the
suspension) All
Ram
Truck
and
Ramcharger vehicles
are

equipped with leaf-type rear springs.
The
springs
have
a
one-piece, rubber bushing pressed into their main leaf front
eye.
Model
150 and
Ramcharger
ve­

hicles
are
equipped with
a
fixed-rate type leaf spring. Progressive-rate type rear leaf springs
are
standard equipment
for all
Model
250 and 350
vehicles.

AXLES
The
8 3/8, 9
1/4-Inch
,
Model
60 and 70
axle hous­
ings consist
of a
cast iron center section. They also
have
two
steel axle shaft tubes that
are
pressed into and welded
to the
differential housing. The removable, stamped steel cover provides
a

means
for
inspection
and
service without removing
the complete axle from
the
vehicle. Both axle types
are
equipped with
a
remote vent
fitting. A small, stamped metal axle gear ratio identifica­
tion
tag is
attached
to the
housing cover. The rear wheel anti-lock (RWAL) brake speed sen­
sor
is
attached
to the top,
forward exterior
of the dif­

ferential housing.
A
seal
is
located between
the
sensor
and the
wire harness connector.
The
seal
must
be
in-plaee when
the
wire connector
is
connected
to the
sensor.
The
RWAL brake exciter
ring
is
press-fitted onto
the
differential case against
the flange. A rear axle equipped with
a
Sure-Grip differential
is optionally available
for
both
Ram
Truck
and
Ram­
charger vehicles.
The
Sure-Grip
has a
two-piece case
that
is
interchangeable with
a
standard differential.
A limited-slip differential
is
optional
on
Model
60,

and
70
rear axles.
The
Model
60
uses
the
Trac-Lok
differential
and the
Model
70
uses
the
Power-Lok
dif­

ferential.
The
Trac-Lok differential uses
a
one-piece case while
the
Power-Lok differential uses
a two-

piece case. Both
use the
same internal components
as
a standard differential, plus
two
clutch disc packs.
IDENTIFICATION The axle differential covers
can be
used
for
identi­
fication (Fig.
1, 2, 3).
Model
60
axle
has the
assembly part number
and

gear ratio listed
on a tag. The tag is
attached
to the
left side
of the
housing cover
(Fig. 3).
Build date
identification codes
on
axles
are
stamped
on the
axle
shaft tube cover side.

LUBRICANTS
Multi-purpose, hypoid gear lubricant should
be

used
for
rear axles with either
a
standard
or a
Sure- Grip differential.
The
lubricant should have MIL-L-
2105-B
and by API GL 5
quality specifications.
MOPAR Hypoid Gear Lubricant conforms
to
both
of

these specifications.
In
addition,
4
ounces
of
Hypoid Additive must
be
included with
a
re-fill
for
Sure-Grip differentials.
If
the
rear axle
is
submerged
in
water,
the lu­

bricant must
be
replaced immediately. Avoid axle failure resulting from water contamination
of
the
lubricant.

REAR
SUSPENSION
AND
AXLE