DODGE TRUCK 1993 Service Manual PDF

J9202-105

Fig. 1 Model 44 Front Axle

FRONT
SUSPENSION
AND
AXLE
2 - 19

DRAIN
AND
REFILL

(1) Drive the vehicle until the gear lubricant
reaches normal operating temperature. (2) Raise and support the vehicle.
(3) Remove the lubricant fill hole plug from the
differential housing cover.
(4) Remove the differential housing cover. Allow
the original lubricant to completely drain from the
housing and axle shaft tubes.
(5) With standard differential, clean the differen­
tial and the housing cavity with a flushing oil (or light engine oil). This will remove the residual lubri­cant and foreign matter. Do not use water, steam,
kerosene or gasoline for flushing. (6) Scrape the residual gasket from the housing
and cover mating surfaces. Clean the mating sur­
faces with mineral spirits. Install a new cover gas­ ket. Apply a bead of MOPAR® Silicone Rubber Sealant on the housing cover (Fig. 2). Allow the
sealant to cure for a few minutes.

SEALING

SURFACE
CONTOUR
OF
BEAD
BEAD

THICKNESS

6.35mm
(1/4")
J9302-30

Fig.
2 Sealant On
Housing
Cover

Install the housing cover within 5 minutes af­
ter applying the sealant. If not installed the seal­ ant must be removed and another bead applied.
(7) Install the cover on the differential with the

bolts.
Install the identification tag. Tighten the cover
bolts to 47 Nnn (35 ft. lbs.) torque.

CAUTION:
Overfilling the
differential
can result in
the lubricant
foaming
and overheating.
(8) Refill the differential housing with the speci­
fied quantity of MOPAR® Hypoid Gear Lubricant.
(9) Install the fill hole plug and tighten to 34 N#m
(25 ft. lbs.) torque.
(10) Road test the vehicle.
PINION
SHAFT
SEAL

REMOVAL
(1) Raise and support the vehicle.
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to prevent damage to the rear U-joint.
(4) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 3).
(5) Mark the positions of the yoke and pinion gear
for installation alignment reference.

SPECIAL
TOOL
C-3281

SPECIAL
TOOL
C-452
J9102-31

Fig.
3
Pinion
Yoke
Removal

(6) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).
PINION
SEAL

SPECIAL
TOOL
C-748

Fig.
4
Pinion
Seal
Removal
J9203-55

2
- 20
FRONT SUSPENSION
AND
AXLE

•
INSTALLATION

(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 5) use In­
staller W-147-E and Handle C-4171.

Fig.
5
Pinion
Seal
Installation

(2) Align the installation reference marks and po­
sition the yoke on the pinion gear.
(3) Install the pinion yoke, washer, and nut on
shaft. Tighten the nut to 271-298 N»m (200-220 ft.
lbs.) torque (Fig. 6).
DIFFERENTIAL
Fig.
6 Tightening
Pinion
Shaft Nut (4) Align the installation reference marks and at­
tach the drive shaft to the yoke.
(5) Add API grade GL 5 hypoid gear lubricant to
the differential housing, if necessary.
(6) Lower the vehicle.

HUB, SPINDLE
AND
AXLE SHAFT
REMOVAL/DISASSEMBLY
(1) Raise and support the front of vehicle.
(2) Remove the wheel/tire.
(3) Remove the brake caliper and adapter, refer to
Group 5, Brakes. Support the caliper to the frame
structure with wire.
(4) Remove the dust cap and drive hub snap ring
(Fig. 7).

Fig.
7 Drive Hub
Snap Ring

(5) Remove the drive hub and spacer (Fig. 8).
(6) Remove the wheel bearing outer lock nut with
Wrench C-4170-A (Fig. 9). (7) Remove the lock washer and inner lock nut
(Fig. 10).
(8) Remove the hub and rotor assembly from the
spindle.
(9) Remove the nuts that attach the spindle to the
steering knuckle. Remove the spindle from the
knuckle, use a soft faced mallet if necessary to tap
loose (Fig. 11).
(10) Pull the axle shaft (with spacer, seal and
slinger) from the steering knuckle (Fig. 12). (11) Clamp the spindle in a soft-jawed vise. Do not
clamp at the bearing contact surfaces. Remove the
bearing seal. (12) Use Puller D-131 to remove needle bearings
from the spindle (Fig. 13).

•

Fig.
8
Spacer
Removal/Installation

Fig.
9
Wheel
Bearing
Lock
Nut
Removal
ASSEMBL
Y/INSTALLA
TION

(1) Add Wheel Bearing Grease lubricant (NLGI
Grade 2, EP or an equivalent lubricant) to the bear­

ings.
Install a new needle bearing in the spindle with
Installer D-122 and Handle C-4171 (Fig. 14).
(2) Lubricate and install a new spindle seal with
Installer D-155 and Handle C-4171 (Fig. 15).
(3) Install the seal with lip facing the axle shaft
splines (Fig. 16). Lubricate the seal (Fig. 17) with
Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant).
FRONT
SUSPENSION
AND
AXLE
2 - 21

LOCK
WASHER INNER LOCK
NUT

Fig.
10
Lock
Washer
Removal/Installation
Fig.
11
Spindle
Removal
(4) Right side only: carefully install the axle shaft
through the knuckle into the axle housing. Ensure
the axle shaft splines are engaged with the differen­
tial side gears. Avoid damaging the differential
seals.

(5) Left side only: remove the shift motor housing
from axle. Position the shift collar on the intermedi­ ate axle shaft. Install the axle shaft, ensure the axle
shaft splines are engaged with the shift collar. In­ stall the shift motor (ensure the fork is engaged with
the shift collar) and tighten the bolts to 14 Nnn (10
ft. lbs.) torque.
(6) Install the spacer on the axle shaft end.
(7) Install the brake splash shield and spindle on
the steering knuckle. Install new nuts and tighten to 34-41 Nnn (25-35 ft. lbs.) torque (Fig. 18).

2
- 22
FRONT SUSPENSION
AND
AXLE
——
J9202-79
Fig. 12 Axle Shaft Removal
Fig. 13 Spindle Needle Bearing Removal (8) Install the hub and rotor assembly onto the
spindle. Add Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant) to the bear­

ings.

(9) Install the wheel bearing inner lock nut on the
spindle with Wrench C-4170 (Fig. 19). Tighten the
lock nut to 68 N*m (50 ft. lbs.) torque to seat the
bearings.
(10) Loosen the inner lock nut. Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rotating the hub and
rotor assembly.
(11) Back off the inner lock nut 135-150 degrees to
set the free play.
(12) Install the tabbed lock washer in the nearest
hole in the washer (Fig. 8). Install and tighten the outer nut lock with Wrench C-4170 (Fig. 19 ) to 68
N«m (50 ft. lbs.) torque. The end play after the final •
Fig. 14 Spindle Needle Bearing Installation Fig. 15 Seal Installation bearing adjustment should be within 0.001 inch to
0.010 inch (0.03 to 0.25 mm).
(13) Install the spacer, driving hub and ring (Fig.

7,
8). Ensure the ring is seated.
(14) Apply MOPAR® Silicone Rubber Sealant to
the edge of the dust cap and install cap onto hub. (15) Install the brake caliper and adapter, refer to
Group 5, Brakes. (16) Install the wheel and tire, refer to Wheel and
Tire—Installation within this section. Lower the ve­ hicle. STEERING
AXLE
SHAFT

•

FRONT
SUSPENSION
AND
AXLE
2 - 23

RN328

Fig.
17 Lubricating Axle Shaft
Seal

Fig.
18
Spindle
Installation

AXLE SHAFT AND
U-JOINT
SERVICE DISASSEMBLY

(1) Remove the snap rings from the yokes.
Fig.
19
Wheel
Bearing Lock Nut
Installation

(2)
Position the U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.

Fig.
20 Bearing Cap
Removal

(3)
Use a mallet to drive the vertical yoke down­
ward to remove the upper needle bearing and cap out (Fig. 20).

(4)
Reverse the position of the yoke and remove op­
posite needle bearing and cap (Fig. 20).

(5)
Remove the yoke from the spider.
(6)
Position the open ends of the spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove remaining bearings and caps.
(7) Remove the spider from the yoke.
(8) Clean and inspect all the components. Clean
any rust from the axle shaft splines. Retain each
bearing and cap separate. If any component is exces­ sively worn or damaged, replace the U-joint.

2
- 24
FRONT SUSPENSION
AND
AXLE

ASSEMBLY
(1) Insert the needle bearing and cap in one yoke
arm bore. (2) Place the yoke in a vise (Fig. 21) and press the
needle bearing and cap into position. Install the snap
ring.

Fig.
21 Bearing Cap
installation

(3) Remove the yoke from the vise and insert one
end of the spider into the bearing. Insert opposite
bearing and cap in the yoke arm bore by hand and align it with the spider.
(4) Place the yoke in a vise and press the cap into
the yoke arm bore and onto the spider (Fig. 22). YOKE

RH403

Fig.
22 Bearing Cap &
Spider
Installation
(5) Use a short plug or a socket wrench to force the
bearing cap into the correct position and install the snap ring.
(6) Repeat the instructions in steps 1 through 5 for
installing remaining bearings, caps and yoke.
STEERING
KNUCKLE, UPPER
AID
LOWER BALL STUDS

REMOVAL/DISASSEMBLY (1) Remove axle shaft, refer to Hub, Spindle and
Axle Shaft Removal.
(2) Disconnect the tie-rod end from the steering
knuckle arm. (3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts (Fig.
23).
Discard the lower nut.
WRENCH
STEERING KNUCKLE

J9202-83

Fig.
23 Upper
Ball
Stud
Nut
Removal
(4) Separate the steering knuckle from the tube
with a soft hammer (Fig. 24).
RAWHIDE

HAMMER
UPPER
BALL
STUD

STEERING KNUCKLE

J9202-84

Fig.
24 Steering
Knuckle
Removal

•

FRONT
SUSPENSION
AND
AXLE
2 - 25 (5) Remove the sleeve from the upper yoke with
Wrench C-4169 (Fig. 25). Discard the sleeve.

Fig.
25
Sleeve
Removal/Installation
(6) Remove the snap ring retaining the lower ball
stud with Snap Ring Pliers (Fig. 26).

Fig.
26
Snap
Ring
Removal/Installation
(7) Remove the lower ball stud from steering
knuckle with Remover/Installer C-4212-L and Adap­
tor Set C-4288 (Fig. 27).
(8) Re-position the tools and remove the upper ball
stud (Fig. 28).
(9) Clean all components with solvent and dry
with compressed air. Inspect all the components for
Fig.
28 Upper
Ball
Stud
Removal

burrs,
chips, excessive wear and cracks. Replace com­
ponents as necessary.
ASSEMBL Y/INSTALLA TION
(1) Install lower ball stud with Remover/Installer
C-4212-L and Adaptor Set C-4288 (Fig. 29). Install
the snap ring retaining the lower ball stud. Ensure
the ring is seated.
(2) Install the upper ball stud with Remover/In­
staller C-4212-L and Adaptor Set C-4288 (Fig. 30).
Install new rubber boots over both ball studs. Re­
move the steering knuckle from the vise.

2
- 26
FRONT
SUSPENSION
AND
AXLE

•

Fig.
29
Lower
Ball
Stud
Installation

(3) Thread new sleeve into the upper yoke with
Wrench C-4169 (Fig. 25). Allow two threads to re­
main exposed at the top.
(4) Position steering knuckle on the yoke arms. In­
stall a new lower ball stud nut and tighten to 108
Nnn (80 ft. lbs.) torque.
(5) Tighten the sleeve in upper yoke arm to 54 N*
(40 ft. lbs.) torque with Wrench C-4169.
(6) Install the upper ball stud nut and tighten to
136 Nnn (100 ft. lbs.) torque. Tighten the nut until C-4212-L
C-4288-1

J9202-90

Fig.
30 Upper
Ball
Stud
Installation
the cotter pin can be installed. Do not loosen the nut
to align the hole and the slot. Install a new cotter
pin.

VACUUM
SHIFT
MOTOR
VACUUM
CONTROL
SYSTEM
(FIG. 31) The disconnect axle control system consists of;
• Vacuum control switch on the transfer case • Air vent filter
• Shift motor
• Indicator switch
• Vacuum switch
• Two check valves • And a harness Refer to Group 21, Transmissions for addi­
tional information.

NUT

LEFT
ENGINE

MOUNT

LEFT
ENGINE
MOUNT

NUT
ANDyv

WASHER
<C>

VIEW
IN DIRECTION
OF ARROW
W
TORQUE
LET. POUNDS NEWTON

METRES

FULLY SEATED
HAND TIGHTENED
55
IN.
6
15 FT. 20
CLIP

ALIGN
WHITE
TAPE
TO END OF CLIP

VIEW
IN DIRECTION
OF
ARROW Z
WITH
V-6
CLIP.
SHIFT
MOTOR

ROUTE HOSE
TO
REAR
OF
DISTRIBUTOR
VIEW
IN DIRECTION

OF ARROW
Z

VIEW
IN
DIRECTION OF ARROW X

J9102-61
Fig. 31 Disconnect
Axle
Vacuum Hose Routing