wheel DODGE RAM 1999 Service Manual PDF
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 409 of 1691
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 and
pinion flange on differential for reassembly. Remove bolts and "U"
joint straps at pinion flange on differential. Disconnect drive shaft
from differential, and support it 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 (C-3281)\
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.
2) Install pinion flange on pinion with reference mark
aligned. Press pinion flange onto pinion. Install washer and pinion
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 table.
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
table. 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) Raise and support vehicle. Remove front wheels. Reference
mark drive shaft to pinion flange for reassembly. Remove bolts and "U"
joint straps at pinion flange. Remove drive shaft, and support aside.
Remove brake calipers, and support aside with wire. DO NOT allow
calipers to hang from brake hoses.
2) Disconnect ABS sensor harness connectors (if equipped).
Disconnect drag link and tie rod from steering knuckles. Disconnect
shock absorber from axle housing. Disconnect stabilizer bar links at
spring brackets.
3) Disconnect electrical connector and vacuum hoses at vacuum
shift motor. Support axle housing assembly with floor jack. Remove
bolts from upper and lower suspension arms. Lower axle housing
assembly from vehicle and remove.
Installation
To install, reverse removal procedure. Ensure reference marks
on drive shaft and pinion flange align. Tighten suspension arms with
vehicle at normal operating height. Tighten bolt/nuts to
specification. See TORQUE SPECIFICATIONS table. Check axle fluid level
Page 419 of 1691
![DODGE RAM 1999 Service Manual PDF AXLE ASSEMBLY SPECIFICATIONS
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AXLE ASSEMBLY SPECIFICATIONS \
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AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS \
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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.
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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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).
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DRIV E A XLE S - P O W ER -L O K
1999 D odge P ic ku p R 1500
1998-99 DRIVE AXLES
CHRY - Power-Lok
Ram Pickup
IDENTIFICATION
POWER-LOK DIFFERENTIAL APPLICATION \
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Application Axle Ring Axle
Model Gear Size Ratio
Ram Pickup ........ Rear Axle ... 10.5" (266.7 mm) ..... 267 RBI\
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NOTE: For rear axles with limited-slip differentials, see TRAC-LOK
article.
DESCRIPTION & OPERATION
A Rear Beam-Design Iron (RBI) axle is an iron casting axle
and differential housing with axle shaft tubes extending from either
side. Tubes are pressed to form a one-piece full-floating axle
housing.
Power-Lok differential assembly is optional equipment. The
differential assembly is a limited-slip type differential. It is
similar in operation to a conventional type differential, except for 2
clutch packs located at the side gears in the differential case. See
Fig. 1 . Clutch packs provide differential action when required for
turning corners, and transmit equal torque to both wheels when driving
straight ahead.
AXLE RATIO & IDENTIFICATION
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
Ram Pickup ......................................... 3.54:1 & 4.10:1
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WARNING: Whenever rotating wheels, DO NOT use engine to rotate
individual wheels unless both rear wheels are off ground and
vehicle is securely supported.
LUBRICATION
CAPACITY
DRIVE AXLE CAPACITY ( 1) \
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Application Pts. (L)\
Ram Pickup ........................................... ( 2) 7.0 (3.3)
Page 421 of 1691
(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 container of Mopar Gear Oil Friction Modifier when
refilling.
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FLUID TYPE
Use SAE 80W-90 or SAE 90W hypoid gear lubricant with MIL-L-
2105-B and API GL-5 ratings. Also add a container of Mopar Gear Oil
Friction Modifier when refilling.
FLUID DRAIN & REFILL
1) With lubricant of rear axle assembly at normal operating
temperature, raise and support vehicle so rear wheels are free to
rotate. Clean around axle housing cover. Loosen axle housing cover
bolts. Drain lubricant from axle housing. Remove bolts and axle
housing cover.
2) Position differential so hole in differential case faces
down. Wipe all accessible areas of axle housing. Ensure sealing
surfaces on axle housing and cover are clean. 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 30 ft. lbs. (41 N.m). Remove oil
filler plug. Add a container of Mopar Gear Oil Friction Modifier. Fill
axle with gear lube. Install oil filler plug. Lower vehicle.
TROUBLE SHOOTING
DIFFERENTIAL NOISE
1) Ensure differential lubricant is at normal operating
temperature. Road test vehicle. Note if differential noise exists in
turns, but not during straight-ahead driving. Probable cause is
incorrect or insufficient rear axle lubricant or additive.
2) Drain and refill rear axle. See FLUID DRAIN & REFILL under
LUBRICATION. Road test vehicle and note if noise still exists, it may
be necessary to disassemble rear axle so differential can be repaired.
See RBI FULL-FLOATING AXLES article for removal of differential case.
TESTING
NOTE: Power-Lok differential can be tested without removing
differential carrier from axle housing. Either test can be
used to check drive axle.
TEST I
1) Place blocks under both front wheels. Ensure engine is off
and transmission is in Neutral. Release parking brake. Raise one rear
wheel until it is completely clear of the floor. Remove wheel. Install
Adapter (6790) to wheel studs, and tighten securely.
2) Using torque wrench on adapter, rotate axle, and record
torque required. Repeat procedure for remaining rear wheel position.
If rotational torque for either rear wheel is less than 30 ft. lbs.
(41 N.m) or greater than 200 ft. lbs. (271 N.m), Power-Lok unit must\
be replaced or repaired.
Page 422 of 1691
TEST II
1) Drive vehicle until differential lubricant is at normal
operating temperature. Place a piece of Kraft paper over a smooth
Formica board. Place Formica board with Kraft paper under one rear
wheel. Rear wheel should be centered on board on level surface.
2) Block one front tire with a 2" high by 3" wide wooden
block. Start vehicle. With gradual throttle pressure, attempt to
slowly drive vehicle over wooden block.
3) If Kraft paper slips out from under rear wheel before
vehicle drives over wooden block, move Formica board and Kraft paper
under the other rear wheel.
4) With gradual throttle pressure, attempt to slowly drive
vehicle over wooden block again. If vehicle drives over wooden block
with Formica and Kraft paper under either rear wheel, drive axle is
functioning properly.
REMOVAL & INSTALLATION
Servicing procedure is same as that used for a standard
differential. See appropriate RBI FULL-FLOATING AXLES article for
servicing procedures.
OVERHAUL
DIFFERENTIAL CARRIER
CAUTION: Mark all component locations for reassembly reference. Note
position of clutch pack components before removal. Install
clutch pack components in correct order and original
locations.
Disassembly
1) Place reference mark on differential case lower half and
upper half for reassembly reference. Also place reference mark on
pinion cross shaft and differential case lower half for reassembly
reference.
2) Remove differential case half retaining bolts. Remove
differential case upper half. Remove components from differential case
lower half. See Fig. 1.
Fig. 1: Exploded View Of Power-Lok Differential
Courtesy of Chrysler Corp.
Cleaning & Inspection
Clean components with solvent, and dry with compressed air.
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 \
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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
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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) \
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Application Pts. (L)\
Ram Pickup
248 RBI ................................................ 6.3 (3.0)\
Page 425 of 1691
![DODGE RAM 1999 Service Manual PDF 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 Manual PDF 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.
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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 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\
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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
Page 429 of 1691
![DODGE RAM 1999 Service Manual PDF 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 Manual PDF 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