bolt pattern DODGE RAM 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: RAM, Model: DODGE RAM 1999Pages: 1691, PDF Size: 40.34 MB
Page 412 of 1691
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.
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 in 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 to retain roll pin in place. Remove differential case from
vise.
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.
3) Install ring gear on differential case. Use NEW ring gear
bolts. DO NOT reuse bolts. Tighten bolts evenly in alternating pattern
to specification. See TORQUE SPECIFICATIONS table. Proceed to INITIAL
DIFFERENTIAL BEARING PRELOAD.
Initial Differential Bearing Preload
1) Install dummy bearings on each side of differential case
where differential bearing fits. Use Dummy Bearing (D-345) for 216 FBI\
axle or (D-343) for 248 FBI 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. 2. Pry between bearing cap and
differential case. Pry differential case to right as far as possible.
Zero dial indicator.
4) Pry differential case to the left as far as possible. Note
dial indicator reading. This reading is referred to as the
"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.
Page 418 of 1691
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. 1. Use Axle Housing Spreader (W-
129-B). Install hold-down clamps. Tighten turnbuckle on axle housing
spreader finger tight.
14) Install pilot stud and dial indicator on axle housing.
See Fig. 1 . 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
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
bearing cap bolts, and tighten 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. 6 . 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 minimum
point, ring gear backlash should not exceed .008" (.20 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 specification. See TORQUE
SPECIFICATIONS table. Fill differential with gear lube. See
LUBRICATION.
Fig. 6: Checking Ring Gear Backlash
Courtesy of Chrysler Corp.
Page 423 of 1691
Inspect clutch components for scoring, wear or damage. Replace
components if necessary.
NOTE: If any clutch pack components are defective, replace both
clutch packs.
NOTE: Ensure axle shaft is positioned in vise so splines on axle
shaft extend approximately 3.00" (76.2 mm) above top of
vise.
Reassembly
1) Place axle shaft that was removed from differential in
soft-jaw vise with splines facing upward to serve as an alignment
device for component assembly.
2) Lubricate all components with gear lube. Assemble
components on axle shaft. Ensure all clutch plates are saturated with
gear lube. Install all clutch components and clutch ring on each side
gear. Ensure components are installed in proper sequence and in
original location. See Fig. 1.
3) Align all tabs on clutch plates, and secure with retaining
clips. Remove clutch component/side gear assembly from axle shaft.
Install assembly in differential case lower half. Ensure clutch is
fully seated in differential case lower half.
4) Install pinion cross shaft and pinion gears is
differential case lower half. Ensure reference marks on pinion cross
shaft and differential case lower half are aligned.
5) Install remaining clutch components and side gear on
differential case lower half. Install differential case upper half on
differential case lower half with reference marks aligned.
6) Install differential case half retaining bolts finger
tight. Place differential case assembly on axle shaft mounted in vise.
Ensure splines on axle shaft engage with side gear splines.
7) Install other axle shaft through differential case upper
half and into side gear. Ensure splines on axle shaft engage with side
gear splines. This must be done to ensure proper alignment of all
components.
NOTE: Different grade differential case half retaining bolts may be
used. Note number of radial lines on head of the bolt before
tightening bolts, as different torque specifications are
used.
8) Ensure both axle shafts are fully engaged. Tighten
differential case half bolts evenly in alternating pattern to
specification. See TORQUE SPECIFICATIONS table.
9) Remove axle shaft. Remove differential case assembly from
axle shaft in vise. Ensure pinion cross shaft is relatively tight on
its ramp. Clearance should not exceed .010" (.25 mm) and should be
equal at all 4 areas.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Applications Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .................................... 30 (41)\
Differential Case Half Bolt
7 Radial Lines Or No. 180 Stamp ................. 90-100 (122-136)\
All Others ......................................... 65-70 (88-95)\
\
\
\
\
\
\
\
Page 429 of 1691
![DODGE RAM 1999 Service Repair 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 Repair 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
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 440 of 1691
axle housing.
CAUTION: DO NOT damage axle shaft bearing in axle housing when
removing axle shaft.
3) Inspect axle shaft-to-axle shaft bearing contact area for
damage. Replace axle shaft and axle shaft bearing if axle shaft is
damaged. Using small pry bar, pry oil seal from axle housing (if
necessary).
4) If replacing axle shaft bearing, use appropriate bearing
puller and slide hammer to remove axle shaft bearing. Rotate threaded
shaft on bearing puller to remove axle shaft bearing.
CAUTION: Ensure axle shaft bearing surface in axle housing is free of
burrs and clean before installing axle shaft bearing.
Installation
1) Using appropriate bearing/seal installer, install bearing.
Ensure axle shaft bearing is bottomed against shoulder in bore.
Install NEW oil seal in axle housing until installer contacts axle
housing.
2) Lubricate axle shaft bearing and oil seal lip with gear
lube. Install axle shaft so splines engage with splines on side gear.
DO NOT damage oil sea when installing axle shaft.
3) Install clip on end of axle shaft. Pull axle shaft
outward, ensuring clip fully seats in counterbore on side gear.
Install pinion shaft ensuring pinion shaft hole aligns with lock bolt
hole.
4) Apply Loctite to CLEAN threads on lock bolt. Install and
tighten lock bolt to specification. See TORQUE SPECIFICATIONS. Ensure
axle housing and axle housing cover sealing surfaces are clean.
5) Apply a 1/4" thick bead of silicone sealant on inside of
bolt holes and along sealing surfaces on axle housing cover. Install
axle housing cover, axle identification tag, and retaining bolts.
Tighten bolts in crisscross pattern to proper specification. See
TORQUE SPECIFICATIONS.
6) To install remaining components, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Fill differential. See LUBRICATION.
DRIVE SHAFT
Removal
1) Raise and support vehicle. Ensure transmission and
transfer case are in Neutral. Scribe mark on drive shaft-to-pinion
flange for reassembly reference.
2) On 2-piece drive shafts, scribe center carrier bearing-to-
frame bracket reference line for reassembly reference. On all drive
shafts, remove bolts and "U" joint straps at pinion flange. Remove
center carrier bearing bolts (if equipped). Remove drive shaft(s).
CAUTION: "U" joint straps and bolts must be replaced. DO NOT 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.
PINION FLANGE & OIL SEAL
CAUTION: Following procedure must be used to retain proper pinion
bearing preload. Failure to follow procedure may result in
premature axle assembly or component failure. Ensure pinion
Page 448 of 1691
ring gear backlash will be checked with same teeth meshed. Rotate ring
gear to point of minimum ring gear backlash.
6) Loosen right adjuster (viewed from rear of axle housing)
and tighten left adjuster until ring gear backlash is .003-.004" (.08-
.10 mm) with each adjuster tightened to 120 INCH lbs. (14 N.m).
7) Rotate pinion back and forth 5-10 times to ensure proper
seating of differential bearings. Ensure ring gear backlash is still
as specified. Tighten bearing cap bolts to specification. See TORQUE
SPECIFICATIONS table.
8) Using adjuster rotator, tighten right adjuster to 75 ft.
lbs. (102 N.m). Rotate pinion back and forth 5-10 times to ensure
proper seating of differential bearings. Continue to tighten right
adjuster until torque remains constant at 75 ft. lbs. (102 N.m).
9) Recheck ring gear backlash at point of minimum ring gear
backlash. If ring gear backlash is not .005-.008" (.13-.20 mm),
increase torque on right adjuster, and seat differential bearings by
rotating pinion. Continue to tighten right adjuster until ring gear
backlash is correct.
10) Tighten left adjuster to 75 ft. lbs. (102 N.m). Rotate
pinion back and forth 5-10 times to ensure proper seating of
differential bearings. Continue to tighten left adjuster until torque
remains constant at 75 ft. lbs. (102 N.m).
11) Check ring gear backlash every 90 degrees to check ring
gear backlash variation. Ring gear backlash variation should not
exceed .003" (.08 mm). For example, if ring gear backlash is .005" (.\
15 mm) at minimum point, ring gear backlash should not exceed .008" (.\
20 mm) anywhere on ring gear.
12) With adjustments completed, install adjuster locks.
Ensure teeth on adjuster lock engages with hole in adjuster. Install
and tighten adjuster lock bolt to specification. See TORQUE
SPECIFICATIONS table.
FINAL INSPECTION & ASSEMBLY
1) With pinion bearing preload and ring gear backlash
properly adjusted, check gear tooth pattern contact. See GEAR TOOTH
CONTACT PATTERNS article in GENERAL INFORMATION.
2) To check side gear clearance, install axle shafts into
axle housing and side gears. Install clip on end of axle shaft. Pull
axle shaft outward, ensuring clip fully seats in counterbore on side
gear.
NOTE: If replacing side gears or side gear thrust washers, check
side gear clearance with axle shaft installed in axle
housing. Check side gear clearance on both side gears.
3) Install equal thickness feeler gauges on each side of side
gear, next to hub of side gear. See Fig. 4. This is side gear
clearance.
Fig. 4: Checking Side Gear Clearance
Courtesy of Chrysler Corp.
4) If no side gear clearance exists, proceed to step 8). If
Page 456 of 1691
Cleaning & Inspection
1) Clean components with solvent and dry with compressed air.
Inspect plates in clutch pack for scoring, wear or damage.
2) Inspect remaining components for damage or wear. Replace
components if necessary.
Reassembly
1) Lubricate clutch pack components with gear lube.
Reassemble clutch packs. Ensure components are installed in correct
sequence and in original location. See Fig. 1. Install clutch pack
retainers on clutch packs.
2) Install clutch packs on respective side gears. Install
differential case on axle shaft. Install clutch pack and lower side
gear in differential case.
3) Install step plate on lower side gear. Install upper side
gear and clutch pack in differential case. Install threaded adapter
disc into upper side gear. Install forcing screw.
4) Tighten forcing screw to compress clutch packs. Install
pinion gears on side gears. Using turning bar, rotate differential
case until hole in differential case is aligned with pinion gears.
Remove turning bar.
5) Lubricate pinion gear thrust washers with gear lube.
Install pinion gear thrust washers. It may be necessary to tighten
forcing screw until pinion gear thrust washers can be installed.
6) Remove forcing screw, step plate and threaded adapter
disc. Using soft-face hammer, tap pinion shaft into differential case.
Install snap rings on pinion shaft (if equipped).
7) Install NEW roll pin. Stake differential case in 2 areas
to retain roll pin. Remove differential case from axle shaft. Install
ring gear on differential case. Install NEW ring gear bolts. DO NOT
reuse bolts. Tighten ring gear bolts evenly in alternating pattern to
specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
\
\
\
\
\
\
Applications Ft. Lbs. (N.m)\
Axle Housing Cover Bolt .............................. 30-35 (41-47)\
Ring Gear Bolt
Dakota ................................................... 70 (95)\
All Others ..................................... 120-140 (163-190)\
\
\
\
\
\
\
\
Page 458 of 1691
Apply multipurpose lubricant (NLGI grade 2 EP) to "U" joints
and slip joint fittings.
INSPECTION
Abnormal vibration and noise can come from many driveline
sources. Drive shaft vibration/noise increases with vehicle speed
(MPH). A vibration that occurs within a specific speed is not caused
by drive shaft imbalance. Before overhauling driveline, check for
other causes/sources of possible vibration/noise.
TIRES & WHEELS
Check tire inflation and wheel balance. Check for foreign
objects in tread, damaged tread, mismatched tread patterns or
incorrect tire sizes. Check for bent wheels.
CENTER BEARING
Tighten drive shaft center bearing mounting bolts. If bearing
insulator is deteriorated or oil-soaked, or drive shaft can be moved
up/down in support, replace center bearing support assembly.
ENGINE & TRANSMISSION MOUNTS
Tighten mounting bolts. If rubber mounts are deteriorated or
broken, replace as needed.
DRIVE SHAFT(S)
Check drive shaft(s) for missing weights, broken welds, or
for dents affecting balance. Check for undercoating, mud, snow/ice on
drive shaft(s). Clean shafts thoroughly and test drive.
"U" JOINTS
Check for foreign material lodged in joints and flange/yokes.
Check for loose "U" joint-to-flange mounting bolts. Check for worn "U"
joint needle bearings. Check for Reddish-Brown rust-dust around "U"
joint caps. Replace "U" joints if necessary.
ADJUSTMENTS
CHECKING DRIVE SHAFT PHASING
One-Piece Drive Shafts
1) Ensure "U" joint flanges on either end of drive shaft are
in same plane. See Fig. 2. Drive shafts with slip joints between yokes
often have arrows to aid in alignment. If yokes are not in same plane,
disassemble slip joint from drive shaft splines. Install slip joint
back onto drive shaft splines, aligning "U" joint yokes. Test drive.
2) Single tube type drive shaft has slip joint on outside of
"U" joint yoke (at transmission end). If one-piece tube type drive
shaft yokes are out of alignment, the drive shaft is torque-twisted.
Drive shaft must be replaced.
Page 691 of 1691
CYLINDER BLOCK
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
BLOCK CLEANING
Only cast cylinder blocks should be hot tank cleaned.
Aluminum cylinder blocks should be cleaned using cold tank method.
Cylinder block is cleaned in order to remove carbon deposits, gasket
residue and water jacket scale. Remove oil galley plugs, freeze plugs
and cam bearings prior to block cleaning.
BLOCK INSPECTION
Visually inspect the block. Check suspected areas for cracks
using the Dye Penetrant inspection method. Block may be checked for
cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of the
cylinders, the main bearing saddles, near expansion plugs and between
the cylinders and water jackets. Inspect lifter bores for damage.
Inspect all head bolt holes for damaged threads. Threads should be
cleaned using tap to ensure proper head bolt torque. Consult machine
shop concerning possible welding and machining (if required).
CYLINDER BORE INSPECTION
Inspect the bore for scuffing or roughness. Cylinder bore
is dimensionally checked for out-of-round and taper using dial bore
gauge. For determining out-of-round, measure cylinder parallel and
perpendicular to the block centerline. Difference in the 2 readings
is the bore out-of-round. Cylinder bore must be checked at top, middle
and bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and
bottom. If wear has exceeded allowable limits, block must be honed
or bored to next available oversize piston dimension.
CYLINDER HONING
Cylinder must be properly honed to allow new piston rings to
properly seat. Cross-hatching at correct angle and depth is critical
to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used.
Drive hone must be lubricated during operation. Mix equal parts of
kerosene and SAE 20w engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone
from top to bottom of cylinder using even strokes to produce 45 degree
cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone
to extend below cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder
wall with hot soapy water to remove abrasive particles. Blow dry with
compressed air. Coat cleaned cylinder walls with lubricating oil.
DECK WARPAGE
Check deck for damage or warped head sealing surface. Place
a straightedge across gasket surface of the deck. Using feeler gauge,
measure clearance at center of straightedge. Measure across width and