Removal DODGE RAM 1500 1998 2.G Repair Manual

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)

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

(20) Fill differential with lubricant, refer to Lubri-
cation & Maintenance for capacity and lubricant
type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove the 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. 43).
INSTALLATION
(1) Set differential case on Plug 8888.
(2) Install differenial case bearings with Installer
8881 and Handle C-4171 (Fig. 44).
(3) Install differentail case into housing.
PINION GEAR/RING GEAR
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 axle shafts.
(4) Remove differential from housing.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.
Fig. 43 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
Fig. 44 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
DRFRONT AXLE - 9 1/4 AA 3 - 75
DIFFERENTIAL (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

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. Adjust backlash or
pinion depth.
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) Raise and support the vehicle.
(2) Position a lift under axle and secure axle to
lift.
(3) Remove wheels and tires assemblies.
(4) Remove all brake components.
(5) Remove axle vent hose.
(6) Mark propeller shaft and companion flange for
installation alignment reference.
(7) Remove propeller shaft.
(8) Remove shock absorbers from axle (Fig. 1).
(9) Remove U-bolts from axle (Fig. 2).
(10) Remove axle from the vehicle.
INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install all brake comonents.
(5) Install axle vent hose.
(6) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(7) Install the wheels and tires.
(8) Fill differential to specifications.
(9) Remove lift from axle and lower the vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets.
Identifying numbers for the ring gear and pinion are
painted onto the pinion gear shaft (Fig. 3) and the
side of the ring gear. A plus (+) number, minus (±)
DRREAR AXLE - 9 1/4 3 - 83
REAR AXLE - 9 1/4 (Continued)

AXLE SHAFTS
REMOVAL
(1) Place transmission in neutral.
(2) Raise and support the vehicle.
(3) Remove wheel and tire assembly.
(4) Remove brake caliper, adapter and rotor (Fig.
19).(5) Remove differential housing cover and drain
lubricant.
(6) Rotate differential case so pinion mate shaft
lock screw is accessible. Remove lock screw and pin-
ion mate shaft from differential case (Fig. 20).
FIXTURE 8136
TRAC-LOK TOOLS 8139
ARBOR DISCS 8541
PINION BLOCK 8542
Fig. 19 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 20 PINION MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION MATE SHAFT
DRREAR AXLE - 9 1/4 3 - 93
REAR AXLE - 9 1/4 (Continued)

(7) Push axle shaft inward and remove axle shaft
C-lock from the axle shaft (Fig. 21).
(8) Remove axle shaft (Fig. 22) carefully to prevent
damage to the shaft bearing and seal in the axle
tube.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Insall axle shaft and engage into side gear
splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.(3) Insert C-lock in end of axle shaft then push
axle shaft outward to seat C-lock in side gear.
(4) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(5) Align hole in shaft with hole in the differential
case and install lock screw with Loctiteton the
threads. Tighten lock screw to 11 N´m (8 ft. lbs.).
(6) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
(7) Install brake rotor, caliper adapter and caliper.
(8) Install wheel and tire.
(9) Remove support and lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal (Fig. 23) from the axle
tube with a small pry bar.
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Coat the lip of thenewseal with axle lubricant
and install a seal with Installer C-4076-B and Han-
dle C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
Fig. 21 AXLE SHAFT C-LOCK
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 22 AXLE SHAFT
1 - AXLE SHAFT
2 - SUPPORT PLATE
3 - CALIPER
4 - PARK BRAKE SHOE ASSEMBLY
Fig. 23 AXLE SHAFT SEAL
1 - AXLE SEAL
2 - AXLE BEARING
3 - 94 REAR AXLE-91/4DR
AXLE SHAFTS (Continued)