sensor DODGE RAM 1999 Service Owners Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 410 of 1691
and fill if necessary.
STEERING KNUCKLES
Removal & Installation
1) Raise and support vehicle. Remove hub bearing and axle
shaft. Remove tie rod or drag link end from steering knuckle arm.
Remove ABS sensor harness and bracket from steering knuckle.
2) Remove cotter pin from upper ball stud nut. Remove upper
and lower ball stud nuts. Using a brass hammer, strike steering
knuckle to remove knuckle from axle tube yokes.
3) To install, reverse removal procedure. On 216 FBI axles,
tighten lower and upper ball stud nuts to specification. See TORQUE
SPECIFICATIONS table.
4) On 248 FBI axles, tighten lower ball stud nut to
specification. DO NOT install cotter pin at this time. Install and
tighten upper ball stud nut to specification. Retorque lower ball stud
nut to specification. See TORQUE SPECIFICATIONS table.
AXLE SHIFT MOTOR
Removal & Installation
1) Disconnect vacuum and wiring connector from shift housing.
Remove indicator switch, shift motor housing cover, gasket and shield
from housing.
2) To install, reverse removal procedure. Ensure shift fork
is correctly guided into shift collar groove. Tighten mounting bolts
to 96 INCH lbs. (11 N.m). Add 5 ounces (148 ml) of GL-5 gear lubrica\
nt
to shift motor housing through indicator switch mounting hole.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential case and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
Disassembly
1) Remove axle shafts from differential. See AXLE SHAFT & HUB
BEARING under REMOVAL & INSTALLATION.
2) Note identification marks on bearing caps and axle housing
for reassembly reference. Bearing caps must be installed in original
location. If marks are not present, place marks on bearing caps and
axle housing.
3) Remove bolts and bearing caps. Place Axle Housing Spreader
(W-129-B) on axle housing so dowel pins engage with locating holes.
See Fig. 1 . Install hold-down clamps. Finger tighten turnbuckle on
axle housing spreader.
4) Install pilot stud and dial indicator on axle housing.
Position dial indicator so stem is resting against opposite side of
axle housing, with pressure on stem.
CAUTION: DO NOT spread axle housing more than .020" (.50 mm), or axle
housing may be damaged.
5) Adjust dial indicator to zero. Tighten turnbuckle enough
to spread axle housing for differential case removal while noting
reading on dial indicator. Dial indicator reading should not exceed .
020" (.50 mm).
Page 419 of 1691
![DODGE RAM 1999 Service Owners Manual AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\](/img/12/56915/w960_56915-418.png "DODGE RAM 1999 Service Owners Manual AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\")
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\
\
Application Specification
Ring Gear Backlash ......................... .005-.008" (.13-.20 mm)\
Ring Gear Backlash Variation .................... ( 1) .002" (.05 mm)
Pinion Bearing Preload
New Bearings ........................... 15-35 INCH Lbs. (2-5 N.m)\
Used Bearings .......................... 10-20 INCH Lbs. (1-2 N.m)\
( 1) - Maximum variation from ring gear backlash measured at
minimum point on ring gear. If ring gear backlash is
.005" (.15 mm) at minimum point, ring gear backlash should
not exceed .007" (.18 mm) anywhere on ring gear.
\
\
\
\
\
\
\
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Applications Ft. Lbs. (N.m)\
ABS Sensor Bolt ................................................ ( 1)
Axle Nut ................................................. 175 (237)\
Ball Joint Stud Nut
216 FBI
Lower .................................................. 80 (109)\
Upper .................................................. 75 (102)\
248 FBI
Lower
1st Time .............................................. 35 (48)\
2nd Time .................................... 140-160 (190-217)\
Upper ................................................... 70 (95)\
Bearing Cap Bolt .......................................... 80 (109)\
Differential Cover Bolt .................................... 30 (41)\
Pinion Nut
216 FBI ........................................ 160-200 (217-271)\
248 FBI ........................................ 215-280 (292-380)\
Ring Gear Bolt
216 FBI ........................................... 70-90 (95-122)\
248 FBI ........................................ 120-140 (163-190)\
Shift Motor Mounting Bolt ...................................... ( 1)
Wheel Bearing Nut ........................................ 125 (170)\
( 1) - Tighten nuts to 96 INCH lbs. (11 N.m).
\
\
\
\
\
\
\
Page 424 of 1691
DRIV E A XLE - R BI F U LL F LO ATIN G A XLE
1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - RBI Full-Floating Axles
Ram Pickup, Ram Van/Wagon
IDENTIFICATION
REAR DRIVE AXLE APPLICATION \
\
\
\
\
\
\
Application Axle Ring Axle
Model Gear Size Ratio
Ram Pickup ....... 248 RBI .......... 9.75" ... 3.55:1 Or 4.10:1
Ram Pickup ....... 267 RBI ......... 10.50" ... 3.54:1 Or 4.10:1
Ram Pickup ....... 286 RBI ......... 11.00" ... 3.54:1 Or 4.10:1
Ram Van/Wagon .... 248 RBI .......... 9.75" ... 3.55:1 Or 4.10:1
\
\
\
\
\
\
\
DESCRIPTION & OPERATION
The Rear Beam-Design Iron (RBI) axle is an iron center
casting (differential housing) with axle shaft tubes extending from
both sides. The tubes are pressed in to form a one-piece axle housing.
Axle contains an integral carrier with hypoid-type ring gear
and pinion with a solid full-floating axle shaft splined into side
gear. Vehicle weight is supported on tubes of axle housing. Axle
shafts may be serviced without disturbing wheel bearings. On vehicles
equipped with Rear Wheel Anti-Lock (RWAL) brakes, a brake sensor is
mounted on top of axle housing and an exciter ring is mounted on ring
gear.
Axles may be equipped with limited-slip differential. Models
248 and 286 RBI use a Trac-Lok differential and Model 267 RBI uses a
Power-Lok differential as optional equipment. Trac-Lok differential
uses a one-piece case. Power-Lok differential uses a 2-piece case.
Both differentials use same internal components as a standard
differential, except 2 clutch packs are used in the differential case.
NOTE: For servicing of limited-slip differential components in
differential case, see appropriate POWER-LOK or TRAC-LOK
article.
AXLE RATIO & IDENTIFICATION
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. For axle ratio, see REAR
DRIVE AXLE APPLICATION table at beginning of article.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
\
\
\
\
\
\
Application Pts. (L)\
Ram Pickup
248 RBI ................................................ 6.3 (3.0)\
Page 425 of 1691
![DODGE RAM 1999 Service Owners Manual 267 RBI ................................................ 7.0 (3.3)\
286 RBI
2WD ................................................... 6.8 (3.2)\
4WD ....................................](/img/12/56915/w960_56915-424.png "DODGE RAM 1999 Service Owners Manual 267 RBI ................................................ 7.0 (3.3)\
286 RBI
2WD ................................................... 6.8 (3.2)\
4WD ....................................")
267 RBI ................................................ 7.0 (3.3)\
286 RBI
2WD ................................................... 6.8 (3.2)\
4WD .................................................. 10.1 (4.8)\
Ram Van/Wagon
248 RBI ................................................ 6.0 (2.8)\
(1) - Approximate drive axle capacity listed. Lubricant level should
be 1/2" below oil filler hole in axle housing cover.
\
\
\
\
\
\
\
FLUID TYPE
Use SAE 80W-90 for 286 models, or 90W for all other models,
hypoid gear lubricant with MIL-L-2105-C and API GL-5 ratings. Models
with Trac-Lok require addition of 6 ozs. (.18 L) Mopar(R) friction
modifier (limited slip additive). Ram Pickups equipped with Power-Lok
require addition of 8 ozs. (.24 L) Mopar(R) friction modifier.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
REAR HUB, BEARINGS & AXLE SHAFT
Removal
Raise and support vehicle. Remove wheel. Remove bolts, axle
shaft and gasket. Remove nut lock from adjusting nut. See Fig. 1.
Remove adjusting nut and outer wheel bearing. Remove rear hub and
brake drum. Remove oil seal and inner wheel bearing (if necessary).
Installation
1) Pack wheel bearings with wheel bearing grease. Install
inner wheel bearing and oil seal in rear hub (if removed). Install
rear hub and brake drum. Install outer wheel bearing and adjusting
nut. Tighten adjusting nut to specification while rotating rear hub
and brake drum. See TORQUE SPECIFICATIONS table.
2) Back off adjusting nut approximately 1/8 turn to obtain .
001-.010" (.03-.25 mm) wheel bearing end play. Tap key lock into
adjusting nut and keyway on axle housing.
3) To install remaining components, reverse removal
procedure. Use NEW gasket when installing axle shaft. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer case selector levers are in Neutral. Remove wheel assembly.
Remove RWAL sensor, if equipped. Reference mark drive shaft to pinion
flange for reassembly.
2) On 2-piece drive shafts, scribe center carrier bearing-to-
frame bracket reference line for reassembly. On all drive shafts,
remove bolts and "U" joint straps at pinion flange. Remove center
carrier bearing bolts, if equipped. Remove spring clamps and brackets.
Remove drive shaft(s).
CAUTION: The "U" joint straps and bolts must be replaced. DO NOT
Page 427 of 1691
nut. Tighten pinion nut while rotating pinion, ensuring bearings are
properly seated. Tighten nut until preload measured before disassembly
is achieved. DO NOT exceed maximum torque specification. See TORQUE
SPECIFICATIONS.
3) To install remaining components, reverse removal procedure
using NEW "U" joint straps and bolts. Ensure all reference marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Check lubricant level and add if necessary.
AXLE HOUSING ASSEMBLY
NOTE: Removing axle housing assembly is not necessary unless axle
housing is damaged. Differential carrier and components can
be serviced by removing differential assembly from axle
housing.
Removal
1) Block brake pedal in upward position, as brake fluid lines
must be disconnected. Raise and support vehicle at body, in front of
rear springs. Remove rear wheels.
2) Reference mark drive shaft to pinion flange for
reassembly. Remove bolts and "U" joint straps at pinion flange. Remove
drive shaft, and support aside.
3) Disconnect and plug brakelines. Disconnect parking brake
cables. Disconnect shock absorbers. On models with Rear Wheel Anti-
Lock (RWAL) brakes, disconnect electrical connector at brake sensor on\
top of axle housing.
4) On all axles, support axle housing assembly with floor
jack. Remove rear spring "U" bolts. Lower axle housing assembly and
remove from vehicle.
Installation
1) To install, reverse removal procedure. Ensure rear spring
center bolts align with holes in spring pads on axle housing assembly.
2) Ensure reference marks on drive shaft and pinion flange
align. Tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS.
Bleed and adjust brakes. Check axle fluid level and fill if necessary.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential case and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
Disassembly
1) On axles with Rear Wheel Anti-Lock (RWAL) brakes, remove
brake sensor from top of axle housing. On all axles, remove axle
shafts from differential. See REAR HUB, BEARINGS & AXLE SHAFT under
REMOVAL & INSTALLATION.
2) Note identification marks on bearing caps and axle housing
for reassembly reference. Bearing caps must be installed in original
location. If marks are not present, place marks on bearing caps and
axle housing.
3) Remove bearing caps. Place Axle Housing Spreader (W-129-B)\
on axle housing so dowel pins engage with locating holes. See Fig. 2.
Install hold-down clamps. Finger tighten turnbuckle on axle housing
spreader.
4) Install Guide Pin (C3288-B) at left side of axle housing.\
Page 437 of 1691
![DODGE RAM 1999 Service Owners Manual AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\
\
Application](/img/12/56915/w960_56915-436.png "DODGE RAM 1999 Service Owners Manual AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\
\
Application")
AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\
\
Application Specification
Ring Gear Backlash
248/267 .................................. .004-.009" (.10-.23 mm)\
286 ...................................... .005-.009" (.13-.23 mm)\
Ring Gear Backlash Variation .................... (1) .002" (.05 mm)
INCH Lbs. (N.m)
Pinion Bearing Preload
New Bearings
Ram Pickup & Wagon .............................. 15-35 (1.7-4.0)\
Ram Van ......................................... 20-40 (2.3-4.5)\
Used Bearings (All Models) ....................... 10-20 (1.1-2.3\
)
( 1) - Maximum variation from ring gear backlash measured at
minimum point on ring gear. If ring gear backlash is
.005" (.15 mm) at minimum point, ring gear backlash should
not exceed .007" (.18 mm) anywhere on ring gear.
\
\
\
\
\
\
\
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Applications Ft. Lbs. (N.m)\
ABS Sensor Bolt
248 & 267 RBI ................................................ ( 1)
286 RBI .................................................. 18 (24)\
Axle Housing Cover Bolt
Ram Pickup ............................................... 30 (41)\
Ram Van/Wagon ............................................ 35 (47)\
Axle-To-Hub Bolt .......................................... 90 (122)\
Bearing Cap Bolt .......................................... 80 (109)\
Fill Hole Plug ............................................. 25 (34)\
Hub Adjustment Nut ............................... 120-140 (163-190)\
Pinion Nut
248 & 267 RBI .................................. 215-330 (292-447)\
286 RBI ........................................ 440-500 (597-678)\
Ring Gear Bolt
248 & 267 RBI .................................. 120-140 (163-190)\
286 RBI ........................................ 200-240 (271-325)\
Shock Absorber Nuts ........................................ 60 (81)\
"U" Joint Strap Bolt ....................................... 14 (19)\
( 1) - Tighten nuts to 97 INCH lbs. (11 N.m).
\
\
\
\
\
\
\
Page 438 of 1691
DRIV E A XLE - 8 .2 5" & 9 .2 5" R IN G G EA R
1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - 8 1/4" & 9 1/4" Ring Gears
Dakota, Ram Pickup, Ram Van/Wagon
NOTE: For models using full-floating axles in which vehicle weight
is supported by axle housing tubes, see RBI FULL-FLOATING
AXLES article.
DESCRIPTION & OPERATION
Drive axle contains a solid semi-floating axle shaft splined
into the side gear. On semi-floating axle shafts, vehicle weight is
supported on axle shaft and bearing. Drive shaft rotates the pinion
which drives the ring gear. Power is transferred from ring gear
through side gears to the axle shafts (hypoid gear type).
On rear axles used in vehicles with Rear Wheel Anti-Lock
(RWAL) brakes, a brake sensor is mounted on top of axle housing, and
an exciter ring is mounted on the differential carrier. See Fig. 1.
Fig. 1: Exploded View Of Drive Axle
Courtesy of Chrysler Corp.
AXLE RATIO & IDENTIFICATION
Page 442 of 1691
from axle housing clips. Disconnect electrical connector from brake
sensor mounted on top of axle housing (if equipped).
4) Disconnect parking brake cables. Scribe mark on drive
shaft and pinion flange for reassembly reference. Remove bolts and "U"
joint straps at pinion flange. Support drive shaft aside to prevent
damage to rear "U" joint.
5) Remove shock absorber from axle housing. Support axle
housing with floor jack. Remove "U" bolt nuts. Remove "U" bolts and
spring brackets. Lower axle housing from vehicle.
Installation
1) To install, reverse removal procedure. Ensure rear spring
center bolts align with holes in spring pads on axle housing.
2) Ensure reference mark on drive shaft and pinion flange are
aligned. Tighten bolt/nuts to proper specification. See TORQUE
SPECIFICATIONS. Bleed and adjust brakes.
DIFFERENTIAL ASSEMBLY
NOTE: Differential assembly consists of differential carrier and
components mounted in axle housing. For differential assembly
servicing, see DIFFERENTIAL ASSEMBLY under OVERHAUL.
OVERHAUL
DIFFERENTIAL ASSEMBLY
NOTE: Check pinion bearing preload, side play and then ring gear
runout, in this order, before disassembling differential
assembly.
Disassembly
1) Remove axle shafts. See AXLE SHAFT & BEARING under REMOVAL
& INSTALLATION. Using INCH-lb. torque wrench, measure amount of force
required to rotate pinion. This is pinion bearing preload. Record
pinion bearing preload for reassembly reference if front pinion
bearing will be replaced.
2) To check side play, place pry bar between differential
carrier and axle housing. Pry differential carrier to one side and
note if any side play exists. No side play should exist. If side play
exists, remove bolt and adjuster lock. See Fig. 1. Using Adjuster
Rotator (C-4164), tighten adjuster to eliminate side play.
3) To check ring gear runout, install dial indicator on axle
housing at 90 degree angle to ring gear, with stem resting against
flat side of ring gear, opposite gear teeth. Rotate ring gear, and
note ring gear runout.
NOTE: Ring gear must be removed from differential carrier before
checking differential carrier flange runout. Differential
carrier and bearings must be reinstalled in axle housing to
check differential carrier flange runout.
4) Mark ring gear and differential carrier at point of
maximum ring gear runout for reassembly reference. If ring gear runout
does not exceed .005" (.13 mm), differential carrier and ring gear are\
okay. If ring gear runout exceeds .005" (.13 mm), check differential
carrier flange runout once ring gear is removed.
5) Remove brake sensor from top of axle housing (if
equipped). Mark bearing caps and axle housing for reassembly
reference.
CAUTION: Mark all bearing races and adjusters in relation to their
Page 449 of 1691
side gear clearance does not exceed .005" (.13 mm), determine if axle
shaft is contacting pinion shaft with feeler gauges installed. If axle
shaft is not contacting pinion shaft, side gear clearance is correct.
5) If side gear clearance exceeds .005" (.13 mm) and axle
shaft is not contacting pinion, record side gear clearance. Remove
pinion shaft, pinion gears, thrust washers, side gear and side gear
thrust washer. Measure thickness of side gear thrust washer.
6) Add thickness of side gear thrust washer to side gear
clearance measurement. This is required thickness of replacement side
gear thrust washer.
7) For example, if side gear clearance was .007" (.18 mm) an\
d
side gear thrust washer thickness is .033" (.84 mm), replacement side
gear thrust washer thickness is .040" (1.02 mm). Install replacement
side gear thrust washer and recheck side gear clearance.
8) If no side gear clearance exists, remove clip and axle
shaft. Remove pinion shaft, pinion gears, thrust washers, side gear
and side gear thrust washer. Measure and record thickness of side gear
thrust washer.
9) Reassemble side gear and components in differential
carrier. Install axle shaft in side gear. DO NOT install clip. Recheck
side gear clearance. If side gear clearance is now less than .012" (.
30 mm), add this measurement to thickness of side gear thrust washer
thickness. This is thickness of replacement side gear thrust washer.
10) If side gear clearance in step 9) is .012" (.30 mm) or
more, both side gears must be replaced and side gear clearance
rechecked. If side gear clearance is still .012" (.30 mm) or more with\
replacement side gears, replace differential carrier.
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS \
\
\
\
\
\
\
Application In. (mm)\
Maximum Differential Carrier Flange Runout .............. .003 (.08)\
Maximum Ring Gear Runout ................................ .005 (.13)\
Ring Gear Backlash ............................. .005-.008 (.13-.20)\
Ring Gear Backlash Variation ( 1) ........................ .003 (.08)
INCH Lbs. (N.m.)
Pinion Bearing Preload
New Bearings ......................................... 10-20 (1-2)\
Used Rear & New Front Bearing ............................. ( 2) 10
( 1) - This is amount of variation in ring gear backlash from reading
obtained at minimum point on ring gear. If ring gear backlash is
.005" (.13 mm) at minimum point, ring gear backlash should not
exceed .008" (.20 mm) anywhere on ring gear.
( 2) - Maximum increase over original pinion bearing preload before
disassembly.
\
\
\
\
\
\
\
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Application Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 35 (47)\
Bearing Cap Bolt ......................................... 100 (136)\
Brake Sensor ............................................... 18 (24)\
Page 471 of 1691
FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES