Front axle DODGE RAM 1500 1998 2.G Repair Manual

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

(2) Install axle shaft bearing Remover C-4660-A (3)
in the bearing (1) (Fig. 29). Then tighten the nut (2)
to spread the remover in the bearing.
(3) Install bearing remove cup (1) bearing (2) and
nut (3) (Fig. 30). Tighten nut (3) to draw the bearing
out.
(4) Inspect axle shaft tube bore for roughness and
burrs.
INSTALLATION
(1) Wipe the axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 5063
and Handle C-4171 (Fig. 31).(3) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(4) Lubricate seal lip with gear lubricant.
(5) Insert axle shaft through seal, bearing and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
(6) Install axle shaft O-ring.
(7) Install skid plate, if necessary.
(8) Install half shaft.
PINION SEAL
REMOVAL
(1) Remove both half shafts.
(2) Remove front propeller shaft.
(3) Rotate pinion gear three or four times and ver-
ify pinion rotates smoothly.
(4) Record pinion rotating torque with an inch
pound torque wrench, for installation reference (Fig.
32).
(5) Position Holder 6719 against the companion
flange and install a four bolts and washers into the
threaded holes and tighten the bolts.
(6) Remove pinion nut.
(7) Remove companion flange with Remover C-452
(Fig. 33).
(8) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
Fig. 30 BEARING REMOVER CUP
1 - REMOVER CUP
2 - BEARING
3 - NUT
Fig. 31 BEARING INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 32 PINION ROTATING TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
3 - 44 FRONT AXLE - C205FDR
AXLE BEARINGS (Continued)

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install seal with Installer 8695 and Handle
C-4171 (Fig. 34).
(3) Install companion flange onto the pinion with
Installer C-3718 and Holder 6719A.
(4) Position holder against the companion flange
and install four bolts and washers into the threaded
holes. Tighten the bolt and washer so that the holder
is held to the flange.
(5) Install anewpinion nut onto the pinion shaft
and tighten the pinion nut until there is zero bearing
end-play (Fig. 35).CAUTION: Do not exceed 271 N´m (200 ft. lbs.) the
minimum tightening torque when installing the
companion flange at this point. Failure to heed cau-
tion may result in damage.
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. Failure to heed caution may
result in damage.
(6) Record pinion rotating torque using an inch
pound torque wrench. The rotating torque should be
equal to the reading recorded during removal plus an
additional 0.56 N´m (5 in. lbs.) (Fig. 36).
(7) If rotating torque is low, tighten the pinion nut
in 6.8 N´m (5 ft. lbs.) increments until the proper
rotating torque is achieved.
CAUTION: If maximum tightening torque 475 N´m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Failure to heed caution may
result in damage.
(8) Install propeller shaft.
Fig. 33 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 COMPANION FLANGE HOLDER
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 45
PINION SEAL (Continued)

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)

(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears (2) and remove
pinion gears (3) and thrust washers (1) (Fig. 40).
(5) Remove differential side gears and thrust
washers.
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their original locations.
(1) Lubricate differential components with hypoid
gear lubricant.
(2) Install side gears and thrust washers into the
differentail case.
(3) Rotate pinion mate gears and thrust washers
into the differentail case.
(4) Install pinion gear mate shaft.
(5) Align hole in pinion gear mate shaft with hole
in the differential case.
(6) Install roll-pin (3) in the differential case with
a punch (1) and hammer (Fig. 41). Peen edge of roll-
pin hole in differential case in two places 180É apart.
(7) Install ring gear.
Fig. 39 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 40 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 41 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
DRFRONT AXLE - C205F 3 - 47
DIFFERENTIAL (Continued)

INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader W-129-B with the Adapter
Plates 8142-A and install the safety holddown
clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
(3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread housing over 0.50 mm
(0.020 in). Failure to heed caution may result in
damage.
(4) Remove dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain in position on the
bearings and the differential preload shims are
seated in the housing. Tap differential case to ensure
bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader.
(8) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(9) Install axle shafts.
(10) Apply a bead of orange Mopar Axle RTV seal-
ant or equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied. Failure to heed caution may result in dam-
age.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N´m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings (3) from differential case (4)
with Puller C-293-PA (1) Adapters C-293-48 (2) and
Plug C-293-3 (5) (Fig. 42).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 43).
(2) Install differential into the housing.
Fig. 42 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
3 - 48 FRONT AXLE - C205FDR
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft jaw
(Fig. 44).
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 44).
(5) Mark companion yoke and companion flange
for installation reference.
(6) Remove companion flange bolts and tie the pro-
peller shaft to the vehicle underbody.
(7) Rotate companion flange three or four times
and verify flange rotates smoothly.
(8) Record pinion rotating torque an inch pound
torque wrench for installation reference (Fig. 45).
(9) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(10) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so that
the Holder 6719 is held to the flange.(11) Remove the pinion nut.
(12) Remove the companion flange with Remover
C-452 (Fig. 46).
(13) Remove pinion from differential housing.
(14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
(15) Remove oil slinger, if equipped and front pin-
ion bearing.
(16) Remove front pinion bearing cup with
Remover 8831 and Handle C-4171 (Fig. 47).
Fig. 43 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 44 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 45 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 49
DIFFERENTIAL CASE BEARINGS (Continued)

(17) Remove rear pinion bearing cup from housing
(Fig. 48) with Remover 8401 and Handle C-4171.
(18) Remove collapsible preload spacer (Fig. 49).
(19) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-42 (Fig. 50).(20) Remove depth shims from the pinion shaft
and record thickness of shims.
Fig. 46 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 47 FRONT PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 48 REAR PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 49 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
3 - 50 FRONT AXLE - C205FDR
PINION GEAR/RING GEAR (Continued)

INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing 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 lubricant
to outside surface of the bearing cups.
(2) Install rear pinion bearing cup with Installer
8692 and Driver Handle C-4171 (Fig. 51).
(3) Install front pinion bearing cup with Installer
8693 and Handle C-4171.
(4) Lubricate front pinion bearing and install bear-
ing in the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal.
(6) Install pinion seal with Installer 8695 and
Handle C-4171 (Fig. 52).
Fig. 50 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFTFig. 51 REAR PINION BEARING CUP
1 - HOUSING
2 - INSTALLER
3 - HANDLE
Fig. 52 PINION SEAL
1 - HANDLE
2 - INSTALLER
DRFRONT AXLE - C205F 3 - 51
PINION GEAR/RING GEAR (Continued)

(7) Place pinion depth shim (Fig. 53) on the pinion
shaft.
(8) Install rear pinion bearing with Installer 6448
and a press (Fig. 54).(9) Installnewcollapsible spacer onto the pinion
shaft (Fig. 55).
(10) Lubricate rear pinion bearing and install the
pinion gear in the housing.
(11) Install companion flange with Installer
C-3718 and Holder 6719.
(12) Installnewpinion nut and tighten to 271
N´m (200 ft. lbs.) (Fig. 56).
(13) Using Holder 6719 and a torque wrench set at
475 N´m (350 ft. lbs.). Tighten pinion nut until bear-
ing end play is taken up.
(14) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until desired rotating torque is achieved.
Measure rotating torque frequently to avoid over-
crushing the collapsible spacer (Fig. 57). The pinion
rotating torque should be:
²Original Bearings: 1 to 2.5 N´m (10 to 20 in.
lbs.)
²New Bearings: 2.0 to 2.8 N´m (18 to 25 in. lbs.)
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. Failure to heed caution may
result in damage.
Fig. 53 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 54 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 55 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
3 - 52 FRONT AXLE - C205FDR
PINION GEAR/RING GEAR (Continued)