DODGE TRUCK 1993 Service Repair Manual

3
- 34
REAR SUSPENSION
AND
AXLE

• (4) Install the spring U-bolts and tighten the nuts
with the specified torque.
(5) Install the shock absorbers.
(6) Connect the parking brake cables.
(7) Connect the brake lines. Install the hubs and
brake drums. Adjust the wheel bearings (refer to Wheel Bearing Adjustment).
(8) Remove the block from the brake pedal. Bleed
and adjust the brakes.
(9) Connect the drive shaft to the pinion yoke with
the reference marks aligned. Tighten the U-joint clamp bolts to 21 N-m (16 ft. lbs./186 in. lbs.) torque.
(10) Install the rear wheels and tighten the lug
nuts with the specified torque (refer to Group 22,
Wheels And Tires). (11) Raise the rear of the vehicle, remove the sup­

ports,
level the vehicle and position the supports. (12) Remove the fill hole plug from the differential
housing cover. Fill the differential housing to the correct level with MOPAR Hypoid Gear Lubricant, or
an equivalent product. Add 4 ounces of MOPAR Hypoid Gear Lubri­
cant Additive for Trac-Lok equipped axles. (13) Install the fill hole plug. Remove the supports
and lower the vehicle. (14) Road test the vehicle to evaluate the results of
the repair.

DIFFERENTIAL
DISASSEMBLY
RE MO VA
L/DISA
SSEMBL Y
Remove the RWAL brake sensor
hold-down

bolt and pull the sensor from the differential
housing. The sensor must be removed to prevent damage when disassembling or assembling the differential components.
(1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 7). (2) Remove the differential bearing caps.
Fig.
7 Bearing Cap
identification
(3) Position Spreader D-167 with the tool dowel
pins seated in the locating holes (Fig. 8). Install the holddown clamps and tighten the tool turnbuckle fin­
ger-tight.

SPECIAL TOOL DIAL

MODEL
44-W-129-A
INDICATOR

Fig.
8
Differential
Housing
Separation
(4) Install a pilot stud at the left side of the differ­
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 8) and zero the indicator.

CAUTION:
Do not
spread
over the specified
dis­

tance. If the
housing
is over-separated, it
could
be distorted or
damaged.

(5) Separate the housing enough to remove the
case from the housing. Separate housing a maxi­
mum distance of 0.38 mm (0.015 in) with the spreader tool. Measure the distance with the dial
indicator (Fig. 8).
(6) Remove the dial indicator. (7) Pry the differential case loose from the hous­
ing. To prevent damage, pivot on housing with the
end of the pry bar against case.
(8) Remove the case from housing. If they are re­
usable, retain the differential bearing cups and bear­ ings together as matched sets.
(9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear

bolts.
Tap the ring gear with a rawhide mallet and
remove (Fig. 9).
(10) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 10).
(11) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).
(12) Remove oil slinger, front bearing and shims
(Fig. 11). Record the thickness of the shims. This will
save time if they should become misplaced.
(13) The excitor ring can be removed with a soft-
faced hammer (Fig. 12). Discard after removal.

REAR SUSPENSION
AND
AXLE
3 - 35

SPECIAL
TOOL
C-3281

EXCITOR
RING RING

GEAR
8903-32

Fig.
9
Ring
Gear
Removal

(14) Remove the front pinion bearing cup with Re­
mover D-158 and Handle C-4171 (Fig. 13).
(15) Remove the rear bearing cup from housing

(Fig.
14).
• Model 60 use Remover D-162 and Handle C-4171
SPECIAL
TOOL

C-452
J9102-31

Fig.
10
Pinion
Yoke
Removal
• Model 70 use Remover D-159 and Handle C-4171
(16) Remove the depth shims from the housing

bore.
Record the thickness of the depth shims.
(17) Remove the pinion rear bearing (Fig. 15);
• Model 60 use Puller DD-914-P, Adapter Ring DD-
914-9 and Plate C-293-37
• Model 70 use Puller DD-914-P, Adapter Ring DD-
914-9 and Plate DD-914-95 (18) Remove the differential side gears and thrust

washers.

PINION
YOKE
WASHER

SLINGER

PINION

PRELOAD
SHIMS
FRONT

BEARING
CUP
PINION
NUT
PINION
OIL
SEAL

PINION PRELOAD
SPACER
FRONT

BEARING
CONE

SHOULDER
FOR

'
PINION
PRELOAD
SPACER
J9203-63

Fig.
11
Pinion
Front Bearing and Preload
Shims

3
- 36
REAR SUSPENSION
AND
AXLE

•

FRONT

BEARING
CUP
J9203-57

Fig.
13 Front Bearing Cup
Removal

(19) Remove the case from the vise.
(20) Remove the bearings (Fig. 16) with:
• Remover DD-914-P
• Adapter Ring DD-914-8
• Plate DD-914-62
• Screw Extension DD-914-7 • Button DD-914-42 Use care that adapter rings are placed so they
do not damage the bearing cage.
(21) Remove bearing shims from case hubs and
mark them (with hub identity) for assembly refer­

ence.
Record the thickness of the shims.
PINION

SPECIAL
TOOL
DD-914-9

SPECIAL
TOOL
G293-37

J9203-59

Fig.
15
Pinion
Rear Bearing
Removal
(22) Clamp the differential case in a vise equipped
with soft jaws. Use a pin punch to remove the pinion gear mate shaft lock pin (Fig. 17).
(23) Remove the mate shaft with a drift and ham­
mer (Fig. 18). (24) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 19).

GLEANING/INSPECTION
(1) Wash and clean all components with cleaning
solvent and dry with compressed air.

REAR
SUSPENSION
AND
AXLE
3 - 37

Fig.
16 Differential Bearing
Removal

Fig.
17
Mate
Shaft
Lock
Pin
Removal
Fig.
18
Mate
Shaft
Removal

Do not steam clean the differential compo­

nents.

(2) Clean the axle shaft tubes. Insert a stiff wire
into each tube, attach a clean cloth to the wire at the
THRUST

WASHER

MATE
GEAR
SIDE
GEAR
J9203-61
Fig.
19
Pinion
Mate
Gear
Removal
housing opening. Draw the wire (and cloth) from the
housing outward through the tube.
(3) Inspect the differential and pinion gear bear­

ings.
Inspect the differential case and housing.
• Bearings and cups should have a smooth appear­ ance with no broken/dented surfaces on the bearing
rollers or the roller contact surfaces
• Bearing races must not be distorted or cracked Cup and bearing must be replaced as a
matched sets only. • All machined surfaces in the housing and on bear­
ing caps should be smooth and without any raised
edges
• Pinion gear front and rear bearing cup bores
should be smooth
• Raised metal on shoulders of cup bores should be
removed with a hand stone
(4) Examine the differential pinion gear mate
shaft, pinion gears, side gears and thrust washers for
wear and damage. Replace all defective components.
If either of the differential pinion gears is not
reusable, both gears must be replaced as a matched set only. Do not replace only one gear.
(5) Examine the ring gear and the pinion gear for
worn and chipped teeth. Examine the ring gear for
damaged attaching bolt threads.
If replacement of either gear is necessary, both
must be replaced as a matched set only.
(6) Inspect the pinion yoke for cracks, worn
splines, pitted areas, and a rough/corroded seal con­
tact surface. Repair or replace the yoke as necessary.

3
- 38
REAR SUSPENSION
AND
AXLE

ASSEMBLY

(1) Align the exciter ring tab with the slot in
dif­

ferential case (Fig. 20). Fig. 20 Exciter Ring Alignment
(2) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment (Fig. 21).
Fig. 21 Ring Gear Bolt Hole Alignment
(3) Press the exciter ring onto the differential case
using the ring gear as a pilot (Fig. 22). •

SLOT
8903-36
Fig. 22 Ring Gear Bolt Hole Alignment (4) Install new ring gear bolts and alternately
tighten to;
• Grade 8 bolts to 136-163-N-m (100-120 ft. lbs.)
torque • Grade 9 bolts (7 radial lines) to 169-183 N»m (125- 135 ft. lbs.) torque (5) Lubricate all differential components with hy­
poid gear lubricant.
(6) Install the following components in the differ­
ential case (Fig. 23).
• Differential side gears and thrust washers
• Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
(7) Install and seat the lock pin in the differential
case and mate shaft with a punch and hammer (Fig.

23).
Peen metal part of case over pin in two places.
If replacement gears and thrust washers were
installed, It is not necessary to measure the gear
backlash. Correct fit is due to close machining
tolerances during manufacture.
(8) Place Master Differential Rearing D-343
(D-117) on the case hubs (Fig. 24).
(9) 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. 25).
(10) Insert a small pry bar between the bearing
cap and left side of differential case. Pry the case as
far as possible to right side (Fig. 25). Zero the dial indicator pointer.
(11) Pry the case to left side and record the travel
distance.
The measurement above is the shim thickness
necessary for case zero end-play. The total
thickness will be determined during the ring gear backlash adjustment.
(12) Remove indicator and pilot stud.
(7) Inspect the pinion bearing preload shims (Fig.
1) for cracks, damage and distortion. Install replace­
ment shims (if necessary) for the preload torque ad­
justment.
(8) Inspect the RWAL brake exciter ring for dam­
age and missing teeth. If not removed, ensure the
ring is firmly pressed onto the differential case. Re­
place the ring if loose or damaged.

DIFFERENTIAL
ASSEMBLY

REAR SUSPENSION
AND
AXLE
3 - 39

PUNCH
TOOL
C-3339

MATE
SHAFT

LOCKPIN

J9203-64

Fig.
23 Mate Shaft Pin
installation

SPECIAL
TOOL
D-343

(D-117)
DIFFERENTIAL

CASE

SPECIAL
TOOL
D-343

(D-117)

J9103-20

Fig.
24 Master Bearing Tools On
Hubs
PINION
GEAR
DEPTH INFORMATION
Gears are supplied as matched sets only. The iden­
tifying numbers for the ring and pinion gear are
etched into the face of each gear (Fig. 26). A plus
(
+ )
number, minus (-) number or zero (0) is etched into
the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best teeth contact pattern.
8903-29

Fig.
25
Differential
Case
End Play Measurement

PRODUCTION
NUMBERS
DRIVE
PINION

GEAR
DEPTH
VARIANCE
GEAR
MATCHING NUMBER

(SAME
AS
RING
GEAR
NUMBER)
J9003-100

Fig.
26
Pinion
Gear ID
Numbers

The standard depth is the distance (Fig. 27) from
the centerline of the axle shaft/ring gear to the shoulder of the rear pinion bearing.
• Model 60 axle, the standard depth/distance is 5.000 inches (127.00 mm)
• Model 70 axle, the standard depth/distance is 5.375 inches (136.525 mm) Compensation for depth variance is achieved by
shims placed adjacent to the pinion gear rear bearing
cup (Fig. 28).
If a new gear set is being installed, note the depth
variance etched into the original and new pinion gear. Add or subtract the thickness of the original
depth shims to compensate for the difference in the
depth variances. Refer to the Depth Variance charts.
For Example:

3
- 40
REAR
SUSPENSION
AND
AXLE

•

DEPTH
SETTING
5.000-

BEARING

SHOULDER
CENTER
LINE
OF AXLESHAFT' RING GEAR
J9302-75

Fig.
27
Pinion
Gear Standard Depth/Distance • If a positive marking, this means the shim pack
must decrease by the same number of thousandths
• If a negative marking, this means the shim pack must increase by the same number of thousandths
• If marked zero will use the nominal setting as de­
termined in this procedure Individual depth shims are available in
• 0.003-inch
• 0.005-inch
• 0.010-inch
• 0.030-inch
If original gear set is installed but the depth shims
replaced, measure the thickness of the original depth
shims. Build a replacement pack of depth shims with
the same thickness.
DRIVE

PINION

BEARING
PRELOAD

SPACER/SHIM

\
DRIVE
\ ^
PINION GEAR DEPTH
DIFFERENTIAL
BEARING
SHIM
J9002-32

Fig.
28
Shim
Locations

If equipped, the oil slinger must be measured
and the thickness included with the total shim
pack thickness.
Depth shim thickness for the new pinion gear must
be determined before installing differential case in
housing.

PINION GEAR DEPTH MEASUREMENT AND
ADJUSTMENT
WITH
TOOL
SET D-116 The following gear depth measurement and adjust­
ment procedure involves using Tool Set
D-271.

PINION GEAR DEPTH VARIANCE

OrlflfMil Miiton OrlflfMil Miiton -3
-2
-1
0
+
1

+
2
+
3
+4
+4
+
0.008
+
0.007
+
0.006

+
0.005
+
0.004

+
0.003
+
0.002

+
0.001 0

+
3
+
0.007

+
0.006
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001 0
-0.001

+2
+
0006
+
0.005
+
0.004

+
0.003
+
0.002

+
0.001 0

-0.001
-0.002

+
1
+
0.005
+
0.004

+
0.003
+
0.002
+
0.001
0
-0.001
-0.002

-0.003
0
+
0.004
+
0.003
+
0.002

+
0.001 0
-0001
-0.002

-0.003
-0.004

-1
+
0.003
+
0.002

+
0.001 0
-0.001
-0.002

-0.003

-0.004
-0.005

-2
+
0.002
+
0.001 0
-0.001
-0.002

-0.003
-0.004

-0.005
-0.006

-3
+
0.001
0
-0.001
-0.002

-0.003
-0.004

-0.005

-0.006
-0.007

-4
0
-0.001
-0.002

-0.003
-0.004

-0.005
-0.006
-0.007
-0.008

J8902-46

•

REAR SUSPENSION
AND
AXLE
3 - 41 (1) Insert Master Pinion Block into the differential
housing (Fig. 29);
• Model 60 use Tool D-120
• Model 70 use Tool D-137

Fig.
29
Pinion
Block
In Shaft
Bore

(2) Place Disc D-116-2 on Arbor D-115-3 and posi­
tion in the bearing cradles (Fig. 30). This is the cen­
terline of the ring gear/axle shaft.

Fig.
30
Disc
&
Arbor
In
Housing

(3) Place Pinion Height Block D-116-1 on top of
master pinion block tool and against arbor tool (Fig.

31).

(4) Firmly place Gauge Block D-115-2 and Dial In­
dicator D-106-5 on the lowest step of pinion height
block tool (Fig. 32). Zero the dial indicator pointer.
(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
32).
Slide the gauge block across along the arbor
while observing indicator. Record the longest travel distance, whether inward (-) or outward
(
+
),
indi­
cated by the pointer.
The plunger travel distance indicated, plus or
minus the variance etched in the gear is the re­ quired thickness for the depth shims.
Fig.
31
Pinion
Height
Block
Against
Arbor

Fig.
32
Pinion
Gear Depth Measurement
(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim pack thickness.
(7) Remove the measurement tools from the differ­
ential housing.
(8) Place the depth shims in the pinion gear rear
bearing bore. Install the bearing cup (Fig. 33);
• Model 60 use Installer
D-lll
and Handle C-4171
• Model 70 use Installer C-4204 and Handle C-4171 Ensure the cup is correctly seated. (9) Install the pinion front bearing cup with In­
staller C-4203 and Handle C-4171 (Fig. 34).
(10) Install the rear bearing (and slinger if used)
on the pinion gear with Installer C-3095-A until
completely seated (Fig. 35).
(11) Assemble preload shims onto pinion and in­
stall the pinion gear in housing.
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer C-3718 and Wrench C-3281 (Fig. 36).

3
- 42
REAR
SUSPENSION
AND
AXLE

SPECIAL TOOL
D-111
PRESS

DRIVE

PINION GEAR
SHAFT
REAR BEARING"
INSTALLATION

TOOL
SPECIAL
TOOL
C-4171 J9203-65 DRIVE
PINION GEAR
OIL

SLINGER

J9302-68

Fig.
33
Pinion
Rear Bearing Cup
installation
Fig.
35
Pinion
Rear Bearing
Installation

BEARING
CUP

INSTALLATION
TOOL
C-4203
DRIVER

HANDLE
TOOL

C-4171
SPECIAL

TOOL
C-3718
DIFFERENTIAL

HOUSING

SPECIAL
TOOL

C-3281

Fig.
34
Pinion
Front Bearing Cup
Installation
(13) Tighten the yoke nut to 339-366 N-m (250-270
ft. lbs.) torque. (14) Check bearing preload torque with an inch
pound torque wrench (Fig. 37). The torque necessary
to rotate the pinion gear should be;
• Original Bearings — 1-3 Nnn (10-20 in. lbs.)
• New Bearings — 2-5 Nnn (20-40 in. lbs.)
If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.

38);

• Increase the preload torque, decrease the shim
thickness
• Decrease the preload torque, increase the shim
thickness
J9103-21

Fig.
36
Pinion
Yoke
Installation

(15) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 39).
(16) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 40);
© Model 60 use Installer C-3719-A and Handle C-4735
• Model 70 use Installer C-359 and Handle C-4735 (17) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 36).

•

Fig.
37 Rotating
Pinion
Gear

Fig.
38
Shim
Locations
(18) Install a new yoke nut and tighten to 339-366
Nnn (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. 41). (1) Install the pinion rear bearing cup (Fig. 42);
• Model 60 use Installer D-lll and Handle C-4171
• Model 70 use Installer C-4204 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. 43).
REAR
SUSPENSION
AND
AXLE
3 - 43
C-452
J9102-31
Fig.
39
Pinion
Yoke
Removal

SPECIAL
TOOL
C-4735

J9203-56

Fig.
40
Pinion
Seal
Installation
Assemble C-758-D6 Tool Set as described (Fig.

41);
• Position Spacer (SP-5814 for Model 60) or (SP-5587
for Model 70) 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 pinion bearings in the
housing (Fig. 44). Allow the sleeve to turn several times during the tightening to prevent brinelling the
bearing cups or the bearings.