differential DODGE RAM 1999 Service Owner's Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 426 of 1691
reuse.
Installation
To install, reverse removal procedure using NEW "U" joint
straps and bolts. Ensure all reference marks are aligned. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
PINION FLANGE & OIL SEAL
Removal
1) Raise and support vehicle. Reference mark drive shaft to
pinion flange on differential for reassembly. Remove bolts and "U"
joint straps at pinion flange on differential. Disconnect drive shaft
from differential, and support aside.
2) 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.
3) Remove pinion nut and washer from pinion. Scribe reference
mark on pinion flange and pinion for reassembly. Using Holder (6719)
and appropriate flange remover, remove pinion flange from pinion.
Remove oil seal from axle housing.
Installation
1) Ensure oil seal surface in axle housing is clean. Coat lip
of oil seal with gear lube. Using appropriate oil seal installer and
handle, install oil seal.
Fig. 1: Exploded View Of Rear Axle (Typical)
Courtesy of Chrysler Corp.
2) Install pinion flange on pinion with reference mark
aligned. Press pinion flange onto pinion. Install washer and pinion
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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 428 of 1691
Install pilot stud and dial indicator onto axle housing. Position dial
indicator so stem is resting against opposite side of axle housing,
with pressure on stem.
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).
CAUTION: DO NOT spread axle housing more than .020" (.50 mm), or axle
housing may be damaged.
Fig. 2: Installing Axle Housing Spreader
Courtesy of Chrysler Corp.
6) Remove dial indicator. Pry differential case from axle
housing. If reusing bearing races for differential bearings, mark
bearing race location for reassembly reference. Bearing races must be
installed with same differential bearing.
7) If removing ring gear, place differential case in soft-jaw
vise. Remove and discard ring gear bolts. Using soft-face hammer, tap
ring gear from differential case.
8) On rear axles with Rear Wheel Anti-Lock (RWAL) brakes, us\
e
soft-face hammer to tap exciter ring from differential case if
removing exciter ring. Replace exciter ring if removed from
differential case.
9) On all axles, remove pinion nut and washer from pinion.
Scribe reference mark on pinion flange and pinion if components are to
be reused. Disconnect drive shaft, and wire aside.
10) Using appropriate holder and flange remover, remove
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![DODGE RAM 1999 Service Owners Manual pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembl](/img/12/56915/w960_56915-428.png "DODGE RAM 1999 Service Owners Manual pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembl")
pinion flange from pinion. Remove oil seal from axle housing.
11) Remove slinger (if equipped), pinion bearing and preload\
shim(s). See Fig. 1. Note thickness of preload shims for reassembly
reference in case shims become misplaced.
12) Remove pinion and bearing from axle housing. Using
appropriate remover, remove front (outer) pinion bearing race from
axle housing. Remove rear (inner) pinion bearing race from axle
housing using remover. Remove pinion bearing depth shims from axle
housing. See Fig. 1. Measure and record shim thickness for reassembly
reference.
13) Remove rear (inner) bearing from pinion, using
appropriate puller. Remove differential bearings from differential
case. Remove preload shims from differential case. See Fig. 1.
Identify preload shim location. Record preload shim thickness for
reassembly reference.
14) Clamp differential case in soft-jaw vise. Remove roll pin
from differential case. Tap pinion shaft from differential case.
Remove pinion gears, pinion gear thrust washers, side gears and side
gear thrust washers from differential case.
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect components for wear. Inspect bearings and bearing races for
wear and pitting. Replace bearings and bearing races as a set. Inspect
ring gear and pinion teeth for wear and chipping. Replace ring gear
and pinion gear as matched set.
2) Check differential case for cracks or scoring of side
gears, thrust washers and pinion thrust faces. Check fit of side gears
to differential case and axle shaft splines. Examine shaft of pinion
shaft for scoring or excessive wear.
3) On axles with Rear Wheel Anti-Lock (RWAL) brakes, if
exciter ring is not removed from differential case, ensure exciter
ring fits tightly on differential case and is fully seated.
NOTE: Lubricate all bearings, bearing races, gears and thrust
washers with gear lube during reassembly.
Reassembly & Adjustments
1) Place differential case in soft-jaw vise. Install side
gears, side gear thrust washers, pinion gears and pinion gear thrust
washers into differential case.
2) Rotate side gears until holes in pinion gears and thrust
washers align with holes in differential case. Install pinion shaft.
Install roll pin in differential case. Stake edge of differential case
in 2 areas, 180 degrees apart, to retain roll pin in place. Remove
differential case from vise.
3) On rear axles with Rear Wheel Anti-Lock (RWAL) brakes,
align tab on exciter ring with slot on differential case if installing
exciter ring. Install ring gear on differential case. Install 2 NEW
ring gear bolts to maintain bolt hole alignment. Using press, press
exciter ring onto differential case using ring gear as a pilot.
4) Install ring gear on differential case (if not previously
installed). Install NEW ring gear bolts. Tighten bolts evenly in
alternating pattern to specification. See TORQUE SPECIFICATIONS table.
Proceed to INITIAL DIFFERENTIAL BEARING PRELOAD.
NOTE: Initial differential bearing preload must be performed to
determine thickness of preload shims in order to obtain zero
end play of differential case. Procedure must be performed
before installing pinion in axle housing.
Initial Differential Bearing Preload
1) Install master bearings on each side of differential case
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![DODGE RAM 1999 Service Owners Manual where differential bearing fits. Use Dummy Bearing (D-343) for 248 and\
267 RBI axles, and (D-346) for 286 RBI axle.
2) Install differential case in axle housing. Install bearing
caps on axl](/img/12/56915/w960_56915-429.png "DODGE RAM 1999 Service Owners Manual where differential bearing fits. Use Dummy Bearing (D-343) for 248 and\
267 RBI axles, and (D-346) for 286 RBI axle.
2) Install differential case in axle housing. Install bearing
caps on axl")
where differential bearing fits. Use Dummy Bearing (D-343) for 248 and\
267 RBI axles, and (D-346) for 286 RBI axle.
2) Install differential case in axle housing. Install bearing
caps on axle housing. Ensure bearing caps are installed in original
location. Install bearing cap bolts.
3) Mount dial indicator on axle housing with stem against
back of ring gear. See Fig. 3. Pry between bearing cap and
differential case. Pry differential case to right as far as possible.
Zero dial indicator.
4) Pry differential case to left as far as possible. Note
dial indicator reading. This reading is referred to as differential
case zero end play. Record differential case zero end play reading.
5) Differential case zero end play measurement indicates
thickness of preload shims required to eliminate clearance between
differential bearings and bearing races.
6) Total thickness of preload shims will be determined during
ring gear backlash adjustment. Remove dial indicator, bearing caps and
differential case from axle housing. Proceed to PINION DEPTH
procedure.
Fig. 3: Measuring Differential Case End Play
Courtesy of Chrysler Corp.
Page 432 of 1691
number is stamped on pinion face. This number must be same as number
on ring gear. A pinion depth variance marking is etched on pinion
face. See Fig. 4.
2) Etched marking, in thousandths of an inch, indicates
deviation from standard pinion depth setting. Standard pinion depth
setting is distance from center line of axle shaft to rear pinion
bearing shoulder area. See Fig. 4. Standard pinion depth setting
varies with axle model. See STANDARD PINION DEPTH SETTING table.
STANDARD PINION DEPTH SETTING
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Application In. (mm)\
248 RBI ............................................. 5.000 (127.00)\
267 RBI ............................................. 5.375 (136.52)\
286 RBI ............................................. 5.812 (147.62)\
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3) If original pinion, ring gear and axle housing are being
used, and pinion depth shims are being replaced, determine thickness
of original pinion depth shims. Replace shims with NEW shims of same
thickness.
4) If only pinion and ring gear are being replaced, and
original axle housing is used, note pinion depth variance marking on
old pinion and replacement pinion.
5) Using etched markings and pinion depth shim adjustment
chart, determine amount to be added or subtracted from thickness of
original pinion depth shims. See Fig. 5. For example, if etched
marking is +4 on original pinion and -4 on replacement pinion,
thickness of pinion depth shims should be increased by .008" (.20 mm).\
NOTE: When determining shim thickness, if result is a negative (-)
reading, subtract this amount from thickness of pinion depth
shim pack to obtain thickness of correct shim. If result is
positive (+), add this amount to thickness of pinion depth
shim pack to obtain thickness of correct shim. If result is
zero, this will be nominal standard pinion depth setting and
no shims are required. When using PINION DEPTH SHIM
ADJUSTMENT CHART, thickness of original pinion depth shim
pack must be accurately determined. If original pinion depth
shim pack dimension cannot be accurately determined, pinion
depth gauge set must be used to properly determine pinion
depth setting. Pinion depth gauge set must also be used if
using replacement axle housing. Proceed to DETERMINING PINION
DEPTH USING PINION DEPTH GAUGE SET procedure.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use pinion depth gauge set for all axle models. Place
master pinion block into pinion bore of axle housing. See Fig. 6.
Install discs on arbor. Install arbor in axle housing with discs
positioned in differential bearing bores. See Fig. 6.
2) Install pinion height block on top of master pinion block,
against arbor. Place gauge block with dial indicator on lowest step of
pinion height block. Zero dial indicator with gauge block flat on
pinion height block.
3) Move gauge block so dial indicator stem contacts arbor.
Move gauge block back and forth (perpendicular to arbor) to get
highest reading. This reading is thickness of required pinion depth
shim pack.
4) To select correct shim, note etched markings on end of
Page 435 of 1691
NOTE: Before performing ring gear backlash, note differential case
zero end play obtained during initial differential bearing
preload. See INITIAL DIFFERENTIAL BEARING PRELOAD procedure.
7) Reinstall pinion flange, washer and NEW pinion nut. DO NOT
reuse pinion nut. Tighten pinion nut to specification. See TORQUE
SPECIFICATIONS table. Recheck pinion preload. Proceed to RING GEAR
BACKLASH procedure.
Ring Gear Backlash
1) Install master bearings on each side of differential case
where the differential bearing fits. Use Dummy Bearing (D-343) for 248\
and 267 RBI axles, and (D-346) for 286 RBI axle.
2) Install differential case in axle housing. Install bearing
caps on axle housing. Ensure bearing caps are installed in original
location. Install bearing cap bolts.
3) Mount dial indicator onto axle housing, with stem against
back of ring gear. Ensure pressure exists on stem of dial indicator.
Ensure ring gear and pinion are tightly meshed.
4) Pry between bearing cap and differential case. Pry
differential case as far to right as possible. Zero dial indicator.
5) Pry differential case to left as far as possible, and note
reading on dial indicator. Repeat procedure several times to ensure
proper reading.
6) Measurement obtained determines preload shim thickness
required to eliminate ring gear backlash. Subtract reading obtained in
step 5) from differential case zero end play obtained during initial
differential bearing preload.
7) This is thickness of preload shims that must be installed
on ring gear side of differential case. These preload shims will be
referred to as "ring gear backlash preload shims".
8) Remaining preload shims required to equal differential
case zero end play will be referred as "zero end play preload shims".
9) Remove dial indicator, bearing caps and differential case
from axle housing. Remove master bearings from differential case.
Install ring gear backlash preload shims onto ring gear side of
differential case.
10) Install differential bearing onto ring gear side of
differential case using appropriate bearing installer.
11) Install zero end play preload shims plus an additional .
015" (.38 mm) thick preload shim onto differential case (opposite rin\
g
gear side). Using bearing installer, install differential bearing onto
differential case.
12) Install bearing races on differential bearings. If
reusing original differential bearings and bearing races, ensure
bearing races are installed in original locations.
13) Place axle housing spreader on axle housing so dowel pins
engage with locating holes. See Fig. 2. Use Axle Housing Spreader (W-
129-B). Install hold-down clamps. Finger tighten turnbuckle on axle
housing spreader.
14) Install pilot stud and dial indicator on axle housing.
See Fig. 2 . 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.
15) 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).
16) Remove dial indicator. Install differential case and
Page 436 of 1691
bearing races in axle housing. Ensure differential bearings and races
are fully seated. Remove axle housing spreader.
17) Install bearing caps in original location. Install and
tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS
table. Rotate differential case several times to seat differential
bearings.
18) Using dial indicator, check ring gear backlash. See
Fig. 7. Ensure ring gear backlash is as specified. See AXLE ASSEMBLY
SPECIFICATIONS.
19) If ring gear backlash exceeds specification, move ring
gear toward pinion. If ring gear backlash is less than specification,
move ring gear away from pinion. To change ring gear backlash, move
preload shims from one side of differential case to other.
20) Check ring gear backlash every 90 degrees to check for
variation. Ring gear backlash variation should not exceed .002" (.05
mm). For example, if ring gear backlash is .005" (.15 mm) at the
minimum point, ring gear backlash should not exceed .007" (.18 mm)
anywhere on ring gear.
Final Inspection & Assembly
1) With ring gear backlash properly adjusted, check gear
tooth pattern contact. See GEAR TOOTH CONTACT PATTERNS article in
GENERAL INFORMATION.
2) When differential is complete and correctly adjusted,
install axle housing cover using NEW gasket (if equipped). If gasket
is not available, apply a 1/4" thick bead of silicone sealant on
inside of bolt holes and along sealing surfaces on axle housing cover.
3) Install axle housing cover, axle identification tag and
retaining bolts. Tighten bolts to proper specification. See TORQUE
SPECIFICATIONS. Fill differential with gear lube. See LUBRICATION.
Fig. 7: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.
AXLE ASSEMBLY SPECIFICATIONS
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 439 of 1691
![DODGE RAM 1999 Service Owners Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
\](/img/12/56915/w960_56915-438.png "DODGE RAM 1999 Service Owners Manual NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
\")
NOTE: Axle ratio can be identified by axle identification tag
attached to axle housing cover. See AXLE RATIO SPECIFICATIONS
table.
AXLE RATIO SPECIFICATIONS
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Application Ratio
8 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.90:1
9 1/4" Ring Gear ........................... 3.21:1, 3.55:1 & 3.92:1
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LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
8 1/4" Ring Gears .................................... ( 2) 4.4 (2.1)
9 1/4" Ring Gear ..................................... ( 2) 4.9 (2.3)
( 1) - Approximate drive axle capacity listed. Lubricant level should
be within 1/2" below bottom of oil filler hole in axle housing
cover.
( 2) - Add 5 ounces of (148 ml) Trac-Loc additive.
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FLUID TYPE
Use SAE 80W-90 hypoid gear lubricant with MIL-L-2105-C and
API GL-5 ratings.
TROUBLE SHOOTING
NOTE: See appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
REMOVAL & INSTALLATION
AXLE SHAFT & BEARING
CAUTION: When servicing differential, DO NOT rotate one axle shaft
unless both axles are installed into differential. Rotation
of one axle shaft without other in place may result in
misalignment of side gears in differential. This would
require difficult realignment of side gears before axle
shafts can be installed.
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Clean area around axle housing cover. Loosen axle housing cover bolts.
Drain lubricant from axle housing. Remove bolts and axle housing
cover. Rotate differential carrier for access to lock bolt. See Fig. 1
.
2) Remove lock bolt and pinion shaft from differential
carrier. See Fig. 1. Push axle shaft inward, toward center of vehicle.
Remove clip from groove in end of axle shaft. Remove axle shaft from