Fig DODGE RAM 1500 1998 2.G Workshop Manual

(5) Hold flange with Flange Wrench 8979 (Fig. 26)
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.
(8) Tighten pinion nut in small increments, until
pinion rotating torque is 0.40-0.57 N´m (3-5 in. lbs.)
greater than recorded measurement.
(9) Rotate pinion several times then verify pinion
rotating torque again.
(10) Install axle shafts.
(11) Install propeller shaft with reference marks
aligned.
(12) Check and fill differential if necessary.
DIFFERENTIAL
REMOVAL
(1) Remove lubricant fill hole plug from the differ-
ential housing cover.
(2) Remove differential housing cover and drain
the lubricant from housing.
(3) Remove axle shafts.
(4) Remove adjuster lock bolts and adjuster locks
(Fig. 27).
(5) Mark bearing caps left and right for installa-
tion reference.
(6) Remove bearing cap bolts and remove bearing
caps.
(7) Loosen differential bearing adjusters (Fig. 28)
with Spanner Wrench 8883.
(8) Remove differential case from the housing.
(9) Remove bearing cups and tag them left and
right for installation reference.
Fig. 25 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 26 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 27 ADJUSTER LOCKS
1 - LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
DRREAR AXLE - 10 1/2 AA 3 - 127
PINION SEAL (Continued)

DISASSEMBLY
(1) Remove pinion shaft with a hammer and punch
from the side with the hole in the pinion shaft (Fig.
29).
(2) Rotate one pinion gear with thrust washer
(Fig. 30) to the differential window and remove the
gear.(3) Rotate the other pinion gear with thrust
washer (Fig. 31) to the differential window and
remove the gear.
(4) Remove differential side gears and thrust
washers (Fig. 32).
Fig. 28 BEARING ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
Fig. 29 PINION SHAFT
1 - PINION GEAR
2 - PINION SHAFT
3 - RING GEAR
4 - EXCITER RING
Fig. 30 FRIST PINION GEAR
1 - DIFFERNTIAL CASE WINDOW
2 - PINION GEAR
3 - THRUST WASHER
Fig. 31 SECOND PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - THRUST WASHER
3 - PINION GEAR
3 - 128 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)

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. 33).
(3) Install first pinion gear into the differential
window and side gears. Rotate the pinion gear to the
back of the case (Fig. 34).(4) Install the other pinion gear and thrust
washer. Rotate the gears to align hole in the pinion
gears with hole in the differential case.
(5) Slide pinion shaft into the case and through
the pinion gears. Tap the shaft to seat the pinion
shaft snap-ring into the case (Fig. 35).
Fig. 32 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 33 SIDE GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEAR
Fig. 34 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEARS
3 - PINION GEAR
Fig. 35 PINION SHAFT INSTALLATION
1 - PINION SHAFT SNAP-RING
2 - SIDE GEAR
3 - PINION GEAR
4 - PINION SHAFT
DRREAR AXLE - 10 1/2 AA 3 - 129
DIFFERENTIAL (Continued)

INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
NOTE: A light coat of grease on the cups will hold
them in place during installation.
(4) Install bearing caps and bolts (Fig. 36). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) 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.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings6 Adjuster Holes
²Original Bearings4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 165 N´m (122 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 37).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
Fig. 36 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTERFig. 37 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 130 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)

DIFFERENTIAL TRAC-RITE
DESCRIPTION
The Trac-RiteŸ differential is a helical gear differ-
ential. The differential has two side gears, six pinion
gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on
that side are forced toward the pinion brake shoes.
The pinion brake shoes then cause frictional drag on
the opposite pinion gears and the side gear. These
friction forces transfer the power to the opposite
wheel. Once the frictional forces are overcome, differ-
entiation will occur. The torque will be continually
biased by the frictional forces to the high traction
wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts.
(2) Remove differential case cover locating screws
(Fig. 38).
(3) Remove differential case cover.(4) Remove side gear and thrust washer (Fig. 39).
NOTE: Mark all component locations.
(5) Remove three pinion brake shoes (Fig. 40).
Fig. 38 LOCATION SCREWS
1 - DIFFERENTIAL COVER
2 - LOCATION SCREWS
Fig. 39 SIDE GEAR AND THRUST WASHER
1 - SIDE GEAR
2 - THRUST WASHER
Fig. 40 PINION BRAKE SHOES
1 - BRAKE SHOES
2 - PINION GEARS
DRREAR AXLE - 10 1/2 AA 3 - 131

(6) Remove six pinion gears (Fig. 41).
(7) Remove remaining side gear thrust washer and
spacer.
(8) Remove remaining three pinion brake shoes.
CLEANING
Clean the differential case and gears with light oil
or a lint free cloth.
NOTE: Never use water, steam, kerosene or gaso-
line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be
smoothed with 400 grit emery cloth and polished
out with crocus cloth.
(1) Inspect pinion gears teeth for chips and cracks
(Fig. 42).
(2) Inspect pinion gears shafts and brake shoes for
scratches, flat-spots or worn (Fig. 42).(3) Inspect side gears teeth for chips and cracks
(Fig. 43).
(4) Inspect pinion and side gear bores for scratches
(Fig. 44).
NOTE: If any damage is found the differential must
be replaced as an assembly. Individual components
can not be replaced separately.
Fig. 41 PINION GEARS
1 - PINION GEARS
2 - SIDE GEAR
Fig. 42 PINION GEAR AND BRAKE SHOE
1 - BRAKE SHOES
2 - PINION GEAR
3 - PINION SHAFT
Fig. 43 SIDE GEARS
1 - THRUST WASHERS
2 - SPACER
3 - SIDE GEARS
3 - 132 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL TRAC-RITE (Continued)

ASSEMBLY
NOTE: Install all component in their original loca-
tions.
(1) Lubricate all gears and differential bores with
differential lubricant.
(2) Install one set of pinion brake shoes into the
case bores.
NOTE: Brake shoes can be installed upside down,
but if install wrong pinion gear will not fit.
(3) Install side gear thrust washer, side gear and
spacer (Fig. 45).
(4) Install one set of pinion gears into the bores
next to the brake shoes, with the pinion shaft facing
up.
(5) Install other side gear and thrust washer.
(6) Install other set of pinion gears into the brake
shoes in the case.
(7) Install other set of brake shoes onto the pinion
gears shafts (Fig. 46).
(8) Install differential cover and location screws.
(9) Installnewring gear bolts and tighten to 237
N´m (175 ft. lbs.).
Fig. 44 PINION/SIDE GEAR BORE
1 - PINION BORES
2 - SIDE GEAR BORE
Fig. 45 SIDE GEAR AND SPACER
1 - SPACER
2 - SIDE SPACER
Fig. 46 PINION BRAKE SHOES
1 - BRAKE SHOES
2 - PINION GEARS
DRREAR AXLE - 10 1/2 AA 3 - 133
DIFFERENTIAL TRAC-RITE (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from the housing.
(2) Install Plug 8888 into the end of the case.
(3) Remove differental case bearings with Bearing
Splitter 1130 and Bridge 938 (Fig. 47).
INSTALLATION
(1) Install differenial case bearings with Installer
8956 and Handle C-4171 (Fig. 48).
(2) Install differentail case into housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from axle housing.
Fig. 47 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
Fig. 48 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
3 - 134 REAR AXLE - 10 1/2 AADR

(4) Place differential on Plug 8888 and drive
exciter ring off the differential case with a hammer
and punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flnage nut and washer.
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
Fig. 50 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 51 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
DRREAR AXLE - 10 1/2 AA 3 - 135
PINION GEAR/RING GEAR/TONE RING (Continued)

(9) Remove pinion flange from the pinion with Pin-
ion Flange Puller 8992 (Fig. 52).
(10) Remove pinion gear from housing, with Pinion
Driver 8977 (Fig. 53) and a hammer.
NOTE: Thread the driver on the pinion shaft till it
bottoms out.
(11) Remove pinion seal with a slide hammer or
pry bar.(12) Remove and discard front pinion bearing.
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove collapsible spacer from the pinion
shaft.
(14) Remove rear pinion bearing with Puller
C-293-PA and Adapter Blocks 8879 (Fig. 54).
(15) Remove pinion depth shim from the pinion
gear shaft and record thickness of the shims.
(16) Remove front pinion bearing cup from the
housing with a punch and hammer and discard cup.
CAUTION: Do not reuse front pinion bearing/cup.
(17) Remove rear pinion bearing cup from the
housing with a punch and hammer, if bearing is
going to be replaced.
Fig. 52 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
Fig. 53 PINION DRIVER
1 - PINION SHAFT
2 - PINION DRIVER
Fig. 54 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
3 - 136 REAR AXLE - 10 1/2 AADR
PINION GEAR/RING GEAR/TONE RING (Continued)