Fluid DODGE RAM 1500 1998 2.G Owner's Manual

FRONT AXLE - C205F
TABLE OF CONTENTS
page page
FRONT AXLE - C205F
DIAGNOSIS AND TESTING................27
REMOVAL.............................31
INSTALLATION.........................31
ADJUSTMENTS........................32
SPECIFICATIONS.......................39
SPECIAL TOOLS.......................40
AXLE SHAFTS
REMOVAL.............................43
INSTALLATION.........................43
AXLE SHAFT SEALS
REMOVAL.............................43
INSTALLATION.........................43
AXLE BEARINGS
REMOVAL.............................43INSTALLATION.........................44
PINION SEAL
REMOVAL.............................44
INSTALLATION.........................45
DIFFERENTIAL
REMOVAL.............................46
DISASSEMBLY.........................47
ASSEMBLY............................47
INSTALLATION.........................48
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................48
INSTALLATION.........................48
PINION GEAR/RING GEAR
REMOVAL.............................49
INSTALLATION.........................51
FRONT AXLE - C205F
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. The side gears are loaded dur-
ing turns. They usually do not cause noise during
straight-ahead driving when the gears are unloaded.
A worn pinion mate shaft can also cause a snapping
or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joints/CV joint.
²Worn side-gear thrust washers.
²Worn pinion shaft bore.
DRFRONT AXLE - C205F 3 - 27

Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
DRFRONT AXLE - C205F 3 - 29
FRONT AXLE - C205F (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 30 FRONT AXLE - C205FDR
FRONT AXLE - C205F (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove snap ring from the axle shaft.
(5) Remove axle with Remove 8420A Collar 8420-3
and Slide Hammer C-3752 (Fig. 27).
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Install axle shaft and engage shaft into side
gear. Push firmly on axle shaft to engage snap-ring.
(3) Check the differential fluid level and add fluid
if necessary.
(4) Install half shaft.
(5) Install skid plate, if necessary.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal with a small pry bar.
INSTALLATION
(1) Clean axle shaft bore clean.
(2) Install anewaxle shaft seal with Installer
8694 and Handle C-4171 (Fig. 28).(3) Lubricate seal lip with gear lubricant.
(4) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
(5) Install axle shaft O-ring.
(6) Install skid plate, if necessary.
(7) Install half shaft.
AXLE BEARINGS
REMOVAL
(1) Remove half shaft, axle shaft and seal.
Fig. 27 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 28 SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 29 BEARING REMOVER
1 - AXLE BEARING
2 - NUT
3 - REMOVER
DRFRONT AXLE - C205F 3 - 43

DIFFERENTIAL
REMOVAL
(1) Remove differential housing cover and drain
fluid.
(2) Remove axle shafts.
(3) Loosen bearing cap bolts.
NOTE: Differential bearing cap reference numbers
are stamped on caps and machined flat on the
housing. If reference numbers cannot be found,
make new marks for later reference.
(4) Install Adapter Plates 8142-A onto the housing.
(5) Install Spreader W-129-B onto the adapter
plates (Fig. 37) and tighten the turnbuckle finger-
tight.
(6) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
(7) Spread the housing to remove the differential
case from the housing (Fig. 38). Measure the distance
with the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(8) Remove dial indicator.
(9) While holding the differential case in position,
remove bearing cap bolts and caps.(10) Remove differential from the housing (Fig.
39). Ensure differential bearing cups and shims
remain in position on the differential bearings.
(11) Tag differential bearing cups and shims to
indicate their location.
Fig. 36 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCHFig. 37 ADAPTER PLATES AND SPREADER
1 - ADAPTER PLATE
2 - SPREADER
Fig. 38 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - SPREADER
3 - 46 FRONT AXLE - C205FDR
PINION SEAL (Continued)

FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page page
FRONT AXLE - 9 1/4 AA
DIAGNOSIS AND TESTING................54
REMOVAL.............................57
INSTALLATION.........................58
ADJUSTMENTS........................59
SPECIFICATIONS.......................63
SPECIAL TOOLS.......................64
AXLE SHAFTS
REMOVAL.............................67
DISASSEMBLY.........................68
ASSEMBLY............................69
INSTALLATION.........................69
AXLE SHAFT SEALS
REMOVAL.............................69
INSTALLATION.........................70PINION SEAL
REMOVAL.............................70
INSTALLATION.........................71
DIFFERENTIAL
REMOVAL.............................72
DISASSEMBLY.........................72
ASSEMBLY............................73
INSTALLATION.........................74
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................75
INSTALLATION.........................75
PINION GEAR/RING GEAR
REMOVAL.............................75
INSTALLATION.........................77
FRONT AXLE - 9 1/4 AA
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. The side gears are loaded dur-
ing turns. They usually do not cause noise during
straight-ahead driving when the gears are unloaded.
A worn pinion mate shaft can also cause a snapping
or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint(s).
²Worn side-gear thrust washers.
²Worn pinion shaft bore.
3 - 54 FRONT AXLE - 9 1/4 AADR

Condition Possible Causes Correction
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 56 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) With vehicle in neutral, position vehicle on
hoist.
(2) Remove brake calipers and rotors.
(3) Disconnect ABS wheel speed sensors.
(4) Disconnect axle vent hose.
(5) Remove front propeller shaft.
(6) Remove stabilizer bar links at the axle brack-
ets (Fig. 1).
(7) Disconnect shock absorbers from axle brackets
(Fig. 2).
(8) Remove track bar from the axle bracket (Fig.
3).
(9) Remove tie rod and drag link (Fig. 4) from the
steering knuckles.
(10) Position lift under the axle assembly and
secure axle to lift.
(11) Mark suspension alignment cams for installa-
tion reference.
Fig. 1 STABILIZER LINK
1 - PULLER C-3894-A
2 - LINK
DRFRONT AXLE - 9 1/4 AA 3 - 57
FRONT AXLE - 9 1/4 AA (Continued)

(8) Installnewpinion seal (Fig. 56) with Installer
8882 and Handle C-4171.
(9) Apply a light coat of teflon sealant to the pin-
ion flange splines.
(10) Hold pinion and lightly tap the pinion flange
onto the pinion shaft, until a few threads are show-
ing.
(11) Install pinion flange washer andnewpinion
nut.
(12) Hold pinion flange with Flange Wrench 8979
and tighten pinion nut until end play is taken up.
(13) Rotate pinion several times to seat bearings.
(14) Measure pinion rotating torque with an inch
pound torque wrench (Fig. 57). Tighten pinion nut in
small increments until pinion rotating torque is:
²New Pinion Bearings:1.7-2.8 N´m (15-25 in.
lbs.)
²Original Pinion Bearings:1.1-2.2 N´m (10-20
in. lbs.)
(15) Rotate pinion several times then verify pinion
rotating torque again.
(16) Position the ring gear on differential case and
start twonewring gear bolts.
(17) Install the rest of thenewring gear bolts and
tighten them alternately to seat the ring gear.(18) Torque ring gear bolts to 140 N´m (103 ft.
lbs.).
(19) Install differential in housing.
(20) Measure final rotating torque with an inch
pound torque wrench. The final pinion rotating
torque plus differential case bearing preload is:
²New Bearings:3.4-5.6 N´m (30-50 in. lbs.)
²Original Bearings:2.8-5.1 N´m (25-45 in. lbs.)
(21) Install axle shafts.
(22) Verify ring gear backlash and gear contact
pattern.
(23) Install the propeller shaft with the reference
marks aligned.
(24) Install differential cover with gasket and
tighten to 40 N´m (30 ft. lbs.).
(25) Fill differential with fluid and tighten fill plug
to 32 N´m (24 ft. lbs.).
Fig. 56 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 57 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
DRFRONT AXLE - 9 1/4 AA 3 - 79
PINION GEAR/RING GEAR (Continued)

REAR AXLE-91/4
TABLE OF CONTENTS
page page
REAR AXLE-91/4
DIAGNOSIS AND TESTING................80
REMOVAL.............................83
INSTALLATION.........................83
ADJUSTMENTS........................83
SPECIFICATIONS.......................90
SPECIAL TOOLS.......................90
AXLE SHAFTS
REMOVAL.............................93
INSTALLATION.........................94
AXLE SHAFT SEALS
REMOVAL.............................94
INSTALLATION.........................94
AXLE BEARINGS
REMOVAL.............................95
INSTALLATION.........................95
PINION SEAL
REMOVAL.............................95
INSTALLATION.........................96
DIFFERENTIAL COVER
REMOVAL.............................97INSTALLATION.........................97
DIFFERENTIAL
REMOVAL.............................97
DISASSEMBLY.........................98
ASSEMBLY............................99
INSTALLATION.........................99
DIFFERENTIAL-TRAC-LOK
DESCRIPTION........................100
OPERATION..........................100
DIAGNOSIS AND TESTING...............100
DISASSEMBLY........................101
ASSEMBLY...........................103
DIFFERENTIAL CASE BEARINGS
REMOVAL............................105
INSTALLATION........................106
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................106
INSTALLATION........................108
REAR AXLE-91/4
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly check for:
²Insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearingshave a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Differential bearingsusually produce a low pitch
noise. Differential bearing noise is similar to pinion
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed.
Axle shaft bearingsproduce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
3 - 80 REAR AXLE-91/4DR