Drive shaft DODGE RAM 1500 1998 2.G Owner's Guide

INSTALLATION
(1) Install differential side bearings (3) with
Installer C-4213 (4) and Handle C-4171 (1) (Fig. 53).
(2) Install differential case into housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts.
(4) Remove differential from the differential hous-
ing.
(5) Place differential case in a vise with soft metal
jaw protectors..
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 54).(8) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(9) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
(11) Remove companion flange with Remover
C-452 (Fig. 55).
Fig. 53 DIFFERENTIAL CASE BEARING
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 54 RING GEAR
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 55 COMPANION FLANGE
1 - COMPANION FLANGE
2 - REMOVER
3 - 106 REAR AXLE-91/4DR
DIFFERENTIAL CASE BEARINGS (Continued)

(12)Remove pinion gear from the housing (Fig. 56).
(13) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
(14) Remove front pinion bearing and oil slinger if
equipped.
(15) Remove front pinion bearing cup with
Remover C-4345 and Handle C-4171 (Fig. 57).(16) Remove rear pinion bearing cup from housing
(Fig. 58) with Remover C-4307 and Handle C-4171.
(17) Remove collapsible spacer from the pinion
shaft (Fig. 59).
Fig. 56 PINION GEAR
1 - RAWHIDE HAMMER
Fig. 57 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 58 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 59 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
DRREAR AXLE - 9 1/4 3 - 107
PINION GEAR/RING GEAR/TONE RING (Continued)

(18) Remove rear pinion bearing (Fig. 60) from the
pinion shaft with Puller C-293-PA and Adapters
C-293-37.
(19) Remove pinion depth shim (Fig. 61) from the
pinion shaft and record shim thickness.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Do not replace one gear without
replacing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer to Adjust-
ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent stick
lubricant to outside surface of the pinion bearing
cups.
(2) Install rear pinion bearing cup (Fig. 62) with
Installer C-4308 and Driver Handle C-4171 and ver-
ify cup is seated.
Fig. 60 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
Fig. 61 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 62 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 108 REAR AXLE-91/4DR
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page page
REAR AXLE - 10 1/2 AA
DIAGNOSIS AND TESTING...............112
REMOVAL............................115
INSTALLATION........................116
ADJUSTMENTS.......................116
SPECIFICATIONS......................120
SPECIAL TOOLS.......................120
AXLE SHAFTS
REMOVAL............................124
INSTALLATION........................124
AXLE BEARINGS
REMOVAL............................125
INSTALLATION........................125
PINION SEAL
REMOVAL............................126
INSTALLATION........................126
DIFFERENTIAL
REMOVAL............................127DISASSEMBLY........................128
ASSEMBLY...........................129
INSTALLATION........................130
DIFFERENTIAL TRAC-RITE
DESCRIPTION........................131
OPERATION..........................131
DISASSEMBLY........................131
CLEANING...........................132
INSPECTION.........................132
ASSEMBLY...........................133
DIFFERENTIAL CASE BEARINGS
REMOVAL............................134
INSTALLATION........................134
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................134
INSTALLATION........................137
REAR AXLE - 10 1/2 AA
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. 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 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 - 112 REAR AXLE - 10 1/2 AADR

VIBRATION
Vibration at the rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear and lis-
ten for the noise. A mechanics stethoscope is helpful
in isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
DRREAR AXLE - 10 1/2 AA 3 - 113
REAR AXLE - 10 1/2 AA (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)

(13) Rotate pinion several times to seat bearings.
(14) Measure pinion rotating torque with an inch
pound torque wrench (Fig. 63). 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 237 N´m (175 ft.
lbs.).
(19) If exciter ring was removed, position differen-
tial assembly on differential Plug 8888 (Fig. 64) and
place exciter ring on the differential case.
(20) Install the exciter ring on the differential case
evenly with a hammer and brass punch (Fig. 65).
Drive the ring down until it is seated against the
ring gear.
CAUTION: Do not damage exciter ring teeth during
installation.
(21) Install differential into the housing.
(22) Verify ring gear backlash and gear contact
pattern.
(23) 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.)
(24) Install axle shafts.
(25) Install the propeller shaft with the reference
marks aligned.
(26) Install differential cover with gasket and
tighten bolts to 40 N´m (30 ft. lbs.).
(27) Fill differential with fluid and tighten fill plug
to 32 N´m (24 ft. lbs.).
Fig. 63 PINION ROTATING TORQUE
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 64 EXCITER RING
1 - EXCITER RING
2 - RING GEAR
3 - DIFFERENTIAL PLUG
4 - DIFFERENTIAL CASE
Fig. 65 EXCITER RING INSTALLATION
1 - EXCITER RING
2 - PUNSH
3 - RING GEAR
DRREAR AXLE - 10 1/2 AA 3 - 139
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 11 1/2 AA
TABLE OF CONTENTS
page page
REAR AXLE - 11 1/2 AA
DIAGNOSIS AND TESTING...............140
REMOVAL............................143
INSTALLATION........................144
ADJUSTMENTS.......................144
SPECIFICATIONS......................148
SPECIAL TOOLS.......................148
AXLE SHAFTS
REMOVAL............................152
INSTALLATION........................152
AXLE BEARINGS
REMOVAL............................152
INSTALLATION........................153
PINION SEAL
REMOVAL............................153
INSTALLATION........................154
DIFFERENTIAL
REMOVAL............................155DISASSEMBLY........................155
ASSEMBLY...........................156
INSTALLATION........................157
DIFFERENTIAL TRAC-RITE
DESCRIPTION........................158
OPERATION..........................158
DISASSEMBLY........................158
CLEANING...........................160
INSPECTION.........................160
ASSEMBLY...........................161
DIFFERENTIAL CASE BEARINGS
REMOVAL............................161
INSTALLATION........................161
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................162
INSTALLATION........................164
REAR AXLE - 11 1/2 AA
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. 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 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 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by:
²Worn U-joint(s).
²Worn side gear thrust washers.
²Worn pinion shaft bore.
3 - 140 REAR AXLE - 11 1/2 AADR

VIBRATION
Vibration at the rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear and lis-
ten for the noise. A mechanics stethoscope is helpful
in isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
DRREAR AXLE - 11 1/2 AA 3 - 141
REAR AXLE - 11 1/2 AA (Continued)

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 the housing.
(4) Place differential on Plug 8964. 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 flange nut.
(9) Remove pinion flange from pinion with Pinion
Flange Puller 8992 (Fig. 52).
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
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
3 - 162 REAR AXLE - 11 1/2 AADR
DIFFERENTIAL CASE BEARINGS (Continued)