Fig DODGE RAM 1500 1998 2.G Workshop Manual

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move scooter
block till dial indicator crests the arbor, then record
the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 10).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the dif-
ferential bearings.
Fig. 8 GAUGE TOOLS IN HOUSING
1. PINION HEIGHT BLOCK
2. PINION BLOCK
3. ARBOR
4. ARBOR DISCS
Fig. 9 PINION DEPTH MEASUREMENT
1. DIAL INDICATOR
2. ARBOR
3. SCOOTER BLOCK
Fig. 10 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 60 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(12) Tighten bearing cap bolts to 85 N´m (63 ft.
lbs.).
(13) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig.
11). The backlash should be 0.08-0.25 mm
(0.003-0.010 in) with a preferred backlash of
0.13-0.18 mm (0.005-0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.
GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shortened gear life.
(1) Wipe clean each tooth of the ring gear.(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque to specifica-
tion.
(4) Apply the brakes lightly to create a 14 N´m (10
ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern is correct (Fig. 12). Back-
lash and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
13). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 14).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Ring gear too far away from pinion gear (Fig.
15). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 16).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
Fig. 11 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 12 CORRECT CONTACT PATTERN
Fig. 13 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
DRFRONT AXLE - 9 1/4 AA 3 - 61
FRONT AXLE - 9 1/4 AA (Continued)

²Pinion gear set too low (Fig. 17). Increase pinion
gear height, by increasing the pinion depth shim
thickness.
²Pinion gear set too high (Fig. 18). Decrease pin-
ion depth, by decreasing the pinion depth shim thick-
ness.
Fig. 14 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
Fig. 15 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 16 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 17 LOW PINION HEIGHT
Fig. 18 HIGH PINION HEIGHT
3 - 62 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

AXLE SHAFTS
REMOVAL
(1) With the vehicle in neutral, position vehicle on
hoist.
(2) Remove brake caliper, rotor and ABS wheel
speed sensor if equipped.
(3) Remove axle shaft cotter pin, hub nut and
washer (Fig. 19).(4) Remove four hub bearing bolts (Fig. 20) from
the back of the steering knuckle.
PINION INSTALLER 8982
FLANGE PULLER 8992
BRIDGE 938
Fig. 19 AXLE NUT
1 - AXLE NUT
2 - AXLE
3 - COTTER PIN
Fig. 20 HUB BEARING BOLTS
1 - STUB SHAFT
2 - BEARING BOLTS
3 - AXLE SHAFT
DRFRONT AXLE - 9 1/4 AA 3 - 67
FRONT AXLE - 9 1/4 AA (Continued)

(5) Remove hub bearing from the steering knuckle.
(6) Remove axle shaft (Fig. 21) from steering
knuckle and axle housing.
DISASSEMBLY
Single cardan U-joint components are not service-
able. If defective they must be replaced as a unit.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove the bearing cap retaining snap rings
(Fig. 22).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(2) Locate a socket with an inside diameter that is
larger than the bearing cap. Place the socket
(receiver) against the yoke and around the perimeter
of the bearing cap to be removed.
(3) Locate a socket with an outside diameter that
is smaller than the bearing cap. Place the socket
(driver) against the opposite bearing cap.
(4) Position the yoke with the sockets in a vise
(Fig. 23).
(5) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(6) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(7) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
Fig. 21 STEERING KNUCKLE
1 - KNUCKLE
2 - AXLE SHAFT
Fig. 22 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 23 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET WRENCH
2 - VISE
3 - SMALL-DIAMETER SOCKET WRENCH
3 - 68 FRONT AXLE - 9 1/4 AADR
AXLE SHAFTS (Continued)

ASSEMBLY
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
INSTALLATION
(1) Clean axle shaft and apply a thin film of
Mopar Wheel Bearing Grease to the shaft splines
and hub bore.
(2) Install axle shaft through the steering knuckle
and into the differential side gears (Fig. 24).
(3) Install hub bearing in the knuckle.
(4) Install hub bearing bolts and tighten to 202
N´m (149 ft. lbs.).
(5) Install ABS wheel speed sensor, brake rotor
and caliper.
(6) Install axle washer and nut. Tighten axle nut
to 179 N´m (132 ft. lbs.).
(7) Rotate axle several 5 to 10 times to seat the
wheel bearing.
(8) Tighten axle nut to final torque of 356 N´m
(263 ft. lbs.).
(9) Align nut to next cotter pin hole and install
new cotter pin.
AXLE SHAFT SEALS
REMOVAL
(1) Remove hub bearings and axle shafts.
(2) Remove differential from differential housing.
(3) Remove differential bearing adjusters (Fig. 25).
(4) Remove axle seals (Fig. 26) located behind
adjusters with Receiver 8498 and Extractor 6310.
(5) Install Receiver 8498 into the adjuster bore.
Fig. 24 AXLE SHAFT
1 - AXLE YOKE
2 - AXLE SHAFT
3 - KNUCKLE
Fig. 25 ADJUSTERS
1 - DIFFERENTIAL CASE BEARING ADJUSTERS
2 - DIFFERENTIAL HOUSING
Fig. 26 AXLE SHAFT SEAL
1 - ADJUSTER THREADS
2 - SEAL
DRFRONT AXLE - 9 1/4 AA 3 - 69
AXLE SHAFTS (Continued)

(6) Install Extractor Rod 6310 with Extractor Foot
6310-9 through the receiver and the axle seal (Fig.
27).
(7) Install Extractor Plate 6310-2 and Nut 6310-7
on the extractor rod.
(8) Tighten nut on the extractor rod (Fig. 28) and
pull the seal out and into the receiver.INSTALLATION
(1) Install axle seal on Installer Cups 8885-2 and
position cups with seals into the housing.
NOTE: Seal are installed with the axle guide facing
outward.
(2) Install Turnbuckle 8885-1 (Fig. 29) into the
installer cups and expand the turnbuckle until the
seal bottom out in the housing.
(3) Install differential into the axle housing.
(4) Install axle shaft and hub bearings
PINION SEAL
REMOVAL
(1) Mark the propeller shaft and pinion flange for
installation reference.
(2) Remove propeller shaft.
(3) Remove hub bearings and axle shafts.
(4) Rotate pinion gear three or four times.
(5) Measure and record the torque necessary to
rotate (Fig. 30) the pinion gear with an inch pound
torque wrench.
Fig. 27 SEAL RECEIVER
1 - RECEIVER
2 - EXTRACTOR FOOT
Fig. 28 SEAL EXTRACTOR
1 - EXTRACTOR ROD
2 - EXTRACTOR NUT
Fig. 29 AXLE SEAL INSTALLER
1 - INSTALLER CUP
2 - INSTALLER TURNBUCKLE
3 - INSTALLER CUP
3 - 70 FRONT AXLE - 9 1/4 AADR
AXLE SHAFT SEALS (Continued)

(6) Hold pinion flange with Flange Wrench 8979
(Fig. 31) and remove pinion flange nut and washer.
(7) Remove pinion flange with Pinion Flange
Puller 8992 (Fig. 32).
(8) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Installnewpinion seal with Installer 8882 and
Handle C-4171 (Fig. 33).
(2) Apply a light coat of teflon thread sealant to
the pinion flange splines.(3) Lightly tap the pinion flange onto the pinion
until a few threads are showing.
(4) Install flange washer andnewpinion nut.
(5) Hold flange with Flange Wrench 8979 and
tighten pinion nut until pinion end play is taken up.
(6) Rotate pinion several times to seat bearings.
(7) Measure pinion rotating torque with an inch
pound torque wrench and compare it to recorded
measurement. Tighten pinion nut in small incre-
ments, until pinion rotating torque is 0.40-0.57 N´m
(3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shafts and hub bearings.
(10) Install propeller shaft with reference marks
aligned.
Fig. 30 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 31 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 32 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 33 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
DRFRONT AXLE - 9 1/4 AA 3 - 71
PINION SEAL (Continued)

DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover and drain
lubricant from the housing.
(2) Remove hub bearings and axle shafts.
(3) Remove adjuster lock bolts and adjuster locks
(Fig. 34).
(4) Mark bearing caps left and right for installa-
tion reference.
(5) Remove bearing cap bolts and remove bearing
caps.
(6) Loosen differential bearing adjusters (Fig. 35)
with Spanner Wrench 8883.
(7) Remove differential case from the housing.
(8) Remove bearing cups and tag them left and
right for installation reference.
DISASSEMBLY
(1) Remove pinion shaft lock bolt.
(2) Remove pinion shaft (Fig. 36).
Fig. 34 ADJUSTERS AND LOCKS
1 - ADJUSTER LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
Fig. 35 ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
Fig. 36 PINION SHAFT
1 - PINION SHAFT
2 - PUNCH
3 - PINION GEAR
4 - SIDE GEAR
3 - 72 FRONT AXLE - 9 1/4 AADR

(3) Rotate differential pinion gears to differential
window and remove pinion gears and thrust washers
(Fig. 37).
(4) Remove differential side gears and thrust
washers (Fig. 38).
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their orignial locations.(1) Lubricate all differential components with axle
lubricant.
(2) Install differential side gears and thrust wash-
ers (Fig. 39).
(3) Rotate the one pinion gear with thrust washer
into the differential case (Fig. 40). Then rotate the
other pinion gear with thrust washer into the differ-
ential case.
Fig. 37 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - PINION GEAR
3 - THRUST GEAR
Fig. 38 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 39 SIDE GEARS
1 - DIFFERENTIAL WINDOW
2 - SIDE GEAR
Fig. 40 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEARS
3 - PINION GEAR
DRFRONT AXLE - 9 1/4 AA 3 - 73
DIFFERENTIAL (Continued)