DODGE TRUCK 1993 Service Repair Manual

3
- 12
REAR
SUSPENSION
AND
AXLE

•
HUB

AXLE

SHAFT
DIFFERENTIAL
HOUSING FRONT

BEARING

VENT

FITTING

SEAL
AXLE
AXLE

SHAFT SHAFT

BEARING
TUBE

BEARING
CAP

WASHER
LOCK
STUD

SIDE

GEAR

CLIP
NUT

BOLT

DIFFERENTIAL
BEARING BEARING

CUP

ADJUSTER

LOCK

COVER
BOLT

PLUG
HOUSING

COVER
BOLT
J9003-109

Fig. 1 8 3/8-Inch Or 9 1/4-Inch Axle

•

REAR SUSPENSION
AND
AXLE
3 - 13

SEALANT
1/16-TO

3/32-INCH
(1.59-TO
38-AAM)
THICK
BEAD

DIFFERENTIAL HOUSING
COVER

(TYPICAL)
J9003-85 Fig, 2 Sealant On Homing
Cower

PINION

GEAR
MATE
SHAFT

O

DIFFERENTIAL CASE
LOCK
SCREW
J9003-110

Fig. 3 Pinion Mate Shaft Lock Screw (7) Push the axle shaft in toward the center of the
vehicle. Remove the axle shaft C-clip lock from the axle shaft (Fig. 4).
(8) Remove the axle shaft. Use care to prevent
damage to the axle shaft bearing.
(9)
Inspect the axle shaft bearing contact surface
area for indications of wear. if
wear exists,
the
axle shaft
and
bearing

should be
replaced. Normal bearing
contact on
the shaft
will
be a dull gray and it
could appear
to be lightly
dented.
ADJUSTER
, SIDE

LOCK
^
GEAR
AXLE

SHAFT
•!
C-CLIP LOCK
J9003-111

Fig.
4 Axle Shaft C-Clip
Lock
(10) If any of these conditions exist, the axle shaft
and bearing must be replaced.
The normal appearance will be a dull gray
surface that could appear slightly dented.
AXLE SHAFT SEAL AND BEARING REMOVAL (1) Remove the axle shaft seal with a small pry
bar.
(2) Remove the bearing if it appears damaged or
the axle shaft shows any of the conditions described above. (3) Remove the axle shaft bearing.
• 8 3/8-inch diameter (Fig. 5), use Remover C-4167 and Slide Hammer C-637
• 9
1/4-inch
diameter (Fig. 6), use Remover C-4828
SPECIAL
TOOL

C-637
SPECIAL
TOOL

C-4167

AXLE
SHAFT

TU1E

J9103-11

Fig.
5 Bearing
Removal
(8
3/8-Axle)

3
- 14
REAR SUSPENSION
AND
AXLE
3
- 18
REAR SUSPENSION Fig.
6 Bearing
Removal
(9
1/4-Axle)

(4) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.

CAUTION:
Inspect
the
housing
bore for
burrs.
Re­
move
as
necessary.

BEARING
AND
SEAL
INSTALLATION
Always install a new seal. (1) Wipe the bore in the axle shaft tube clean.
(2) If the original bearing is not reusable, install a
new bearing.
• 8 3/8-Axle use Installer C-4198 with Handle
C-4171
• 9
1/4-Axle
use Installer C-4826 with Handle
C-4171

CAUTION:
DO NOT use the new axle
shaft
seal
to

position
or
seat
the bearing in the axle
shaft
bore.
(3) Insert the bearing into the tube. Ensure that
the bearing is not cocked and is seated firmly against
the tube shoulder.
(4) Install the new axle shaft seal (Fig. 7).
• 8 3/8-Axle use Installer C-4203 and Handle C-4171
• 9
1/4-Axle
use Installer C-4826 and Handle C-4171
SPECIAL
TOOL
SPECIAL
TOOL

Fig.
7 Axle Shaft
Seal
Installation
(5) When the tool cont

(face),
the seal will be a
depth.
AXLE SHAFT INSTALL* (1) Lubricate the bearin
the axle shaft and engage gear. Use care to prevei damaging the axle shaft
(2) Insert the C-clip loi
(Fig. 4). Push the axle s
C-clip lock.
(3) Insert the pinion ge
Install through the thrust
Align the hole in the shaf
Install the lock screw wit
Tighten the screw to 11 Is
3).

(4) Clean the cover anc
Refer to the Drain and Re
(5) Install the brake drv
(6) Install the wheel an
Tire Installation within th
cle.

(7) Raise or lower the
level.
(8) Remove the fill hole
housing with lubricant. I chart for the type and th
hole plug.
(9) Lower the vehicle. T
correct operation.

PINION
SEAL REPLACE!!

CAUTION:
The following

so
the correct pinion bea

tained.
If not completely f
failure
of the rear axle.
REMOVAL (1) Raise and support tr
(2) Mark the U-joint, pi]
for reference.
(3) Disconnect the drh
yoke. Secure the drive sha
prevent damage to the re*
(4) Remove the rear w
drums to prevent any dr
false bearing preload torq
(5) Use a Newton-mete
wrench to measure the p
tate the pinion shaft sev( wrench. Note the indicate moved through several re' (13) Install the brake drums.
(14) Install the wheels. Lower
(15) Adjust hoist so vehicle k
Check the differential housing h
essary, add sufficient amount.

COMPLETE AXLE REMOVAL/IN!
It is not necessary to remov
from the vehicle for routine or d
the differential housing or axle aged, the complete axle can 1
stalled.
REMOVAL (1) Raise the vehicle to a <
height that will permit support t at the front of the rear springs. (2) Block the brake pedal in tl
position with a wooden block. (3) Remove the rear wheels. '.
brake drum retaining clips oi
(4) Disconnect the brake flui
the wheel cylinders. Cap the fit of brake fluid.
(5) Remove the vent hose froi

pie.

(6) Remove the brake tee be
the brake fluid tubes from the c (7) Disconnect the parking bn
U-joint, pinion yoke, and pinion
Mark the U-joint, pinion yol
for reference. (8) Disconnect the drive she
yoke. Secure the drive shaft in a prevent damage to the rear U-jc
(9) Remove the shock absorl
nuts and bolts. Remove the reai
the U-bolts and the spring brad
(10) Remove the complete axL
(11) Wash and clean the outei
ing and tubes. Use an appropri; and dry the surface with comprc

INSTALLATION
(1) Position the rear axle sj
spring center bolts.
(2) Install the spring U-bolts
absorber lower bolts. Tighten tl
fled torque.
(3) Connect the parking brake
(4) Connect the brake fluid
wheel cylinders. Bleed and adjui (5) Align the installation refer
the drive shaft yoke to the pinii U-joint clamp bolts to 19-23 N
torque.
(6) Install the rear wheels. Ti|
correct tightening sequence.

REAR SUSPENSION
ANi
AXLE
3 - 17
(3) Eliminate any side play in the differential case.
Attach Dial Indicator to Pilot stud C-3288-B. Place
the indicator plunger at a right angle (90°) to the ring gear (Fig. 11). The plunger should exert a slight
force against the gear face.

DIAL

INDICATOR

Fig.
11
Ring
Gear
Runout
Measurement
(4) Measure the runout by turning the ring gear
several complete revolutions. Observe the dial indica­
tor pointer. Mark the ring gear and the differential
case at the areas of maximum runout. The ring gear
runout should not exceed 0.005 inch (0.13 mm). If the
runout exceeds 0.005 inch (0.13 mm), a damaged
dif­

ferential case could be the cause.
The marking on the differential case will be
very useful later during the differential case
runout. Remove the rear wheel anti-lock (RWAL) sensor.
(5) Mark the differential housing and the differen­
tial bearing caps for installation reference (Fig. 12).
(6) Remove the bearing threaded adjuster lock
from each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
(7) Loosen the threaded adjusters with Wrench
C-4164 (Fig. 13).
(8) Hold the differential case in place. Remove the
bearing caps (Fig. 14), adjusters and the differential
case.

Each differential bearing cup and threaded
adjuster must be kept with their respective bear­
ing.

PINION
GEAR
SHAFT
REMOVAL
(1) Remove the pinion gear nut and washer. Use
Puller C-452 and Wrench C-3281 to remove the pin­
ion gear yoke.
Fig.
12
Housing
&
Caps
Marked For
Installation

Reference
Fig.
13 Threaded Adjuster Tool

Fig.
14
Differential
Bearing Cap
Removed

(2) Use Puller C-748 to remove the pinion seal.
Discard the seal. (3) Force the pinion gear out the front bearing to

3-18 REAR SUSPENSION
AND
AXLE

• remove the shaft and front bearing. This will dam­
age the front bearing rollers and bearing cup.
The front bearing and cup must be replaced. Discard the bearing collapsible spacer.
(4) Remove the front and rear bearing cups with
Remover C-4306 and Handle C-4171.
(5) Remove the rear bearing from the pinion shaft
with Puller C-293-PA and Adapter (Fig. 15). Remove and record the pinion gear depth shims.
• 8 3/8 use Adapter C-293-42 • 9 1/4 use Adapter C-293-37

SPECIAL
TOOL

C-293-PA

Fig. 15 Inner Bearing Removal
RING GEAR Do not remove the ring gear from case unless
the runout must be measured.
(1) Clamp the case (with the ring gear bolts facing
upward). Use a vise equipped with soft jaws (brass).
(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case

pilots.
Remove the ring gear.
CASE FLANGE RUNOUT MEASUREMENT (1) If the ring gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should also be mea­
sured. Install the case with the bearing cups and the
threaded adjusters close to their original position.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 (Fig. 12) to thread both adjusters inward. Remove all side play.
(3) Attach Dial Indicator to measure the flange
runout. The plunger should contact the ring squarely
between the outer edge and the gear attaching bolt holes (Fig. 16). Fig. 16 Case Flange Runout Measurement
(4) Rotate the differential case several times. Ob­
serve the dial indicator pointer. Mark the area of
maximum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). If the
runout exceeds the amount replace the differential
case.

You can reduce excessive ring gear runout by
positioning the ring gear runout mark 180 de­ grees opposite the flange runout mark.
(5) Remove the differential bearing cap bolts. Re­
move the differential case from the differential hous­ ing.
DIFFERENTIAL CASE DISASSEMBLY (1) Rotate the side gears until the pinion gears are
located at the differential case opening and remove
them.
(2) Remove the side gears and the thrust washers.
(3) Remove the differential bearings from the case
hubs with Puller C-293-PA, Adapter (Fig. 17).
• 8 3/8 use Adapter C-293-48 and Plug SP-3289
• 8 1/4 use Adapter C-293-48 and Plug C-293-3
CLEANING AND INSPECTION (1) Clean all of the differential components in
cleaning solvent. Allow the bearings to either air dry
or dry them with a lint-free cloth. Dry the other com­
ponents with compressed air.
(2) Examine each component for wear or damage.
(3) Replace shims, bearings and cups as a set only.
Replace bearings and cups if either is galled, worn,
cracked, or damaged.
(4) Inspect the differential side and pinion gears.
Replace any gear that is worn, cracked or chipped.
(5) Inspect the differential case. Replace the case if
cracked or damaged.
Polish each axle shaft with No. 600 crocus
cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft seal
contact surface. When polishing, the crocus

•

REAR
SUSPENSION
AND
AXLE
3 - 11

ADAPTERS
Fig.
17
Differential
Bearing
Removal
cloth should be moved around the circumfer­
ence of the shaft (not in-line with the shaft).
When replacing a drive pinion gear bearing,
always replace the bearing and cup as a
matched set only.
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them if necessary.
(7) Test each threaded adjuster to determine if it
rotates freely. (8) If an adjuster binds, repair the damaged
threads or replace the adjuster.

EXCITER
RING
REPLACEMENT
The ring gear must be removed before the RWAL
brake exciter ring can be replaced.
(1) Remove exciter ring with a hammer and drift.
(2) Heat the replacement exciter ring with a heat
lamp or by immersing in a hot fluid. The tempera­
ture should not exceed 149°C (300°F). Do not use a
torch to heat the ring.
(3) After heating, quickly position the exciter ring
on the differential case adjacent to the flange.

DIFFERENTIAL
CASE ASSEMBLY
(1) Lubricate all the differential case components
with gear lubricant. (2) Place the thrust washers on the differential
side gears. Position the gears in the differential case
counterbores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear­ ance Measurement And Adjustment.
(3) Position the thrust washers on the differential
pinion gears. Mesh the pinion gears with the side

gears.
Ensure that the pinion gears are exactly 180 degrees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align these components with the
mate shaft bores in the case.
(5) If the ring gear was removed, clean all contact
surfaces. Use an Arkansas stone or fine file to re­
move any sharp areas from the chamfered inside di­ ameter.
(6) If removed, heat ring gear with a heat lamp or
by immersing in a hot fluid. The temperature should not exceed 149°C (300°F). Do not use a torch to
heat the ring.
(7) Position heated gear on case. Use two equally
spaced Pilot Studs C-3288-B to align the gear with
the flange holes (Fig. 18).

J9203-24

Fig.
18
Case-To-Ring
Gear
Alignment

(8) Install replacement ring gear bolts (with left
hand threads). Alternately and evenly tighten each
bolt to 95 N-m (70 ft. lbs.) torque.

CAUTION:
When
installing a
differential
bearing,
never apply force to the bearing
cage
because
bear­

ing
damage
will
result.
(9) Place a differential bearing on each hub (Fig.

19).

• 8 3/8, use Installer C-4340 and Handle C-4171
• 9 1/4, use Installer C-4213 and Handle C-4171

3
- 20
REAR SUSPENSION
AND
AXLE

•

SPECIAL
TOOL
C-4171

SPECIAL
TOOL

8-3/8-
C-4340
9.1/4-
C-4213
J9203-33
Fig.
19 Differential Bearing Installation

PINION DEPTH MEASUREMENT AND ADJUSTMENT

WITH
GAUGE SET

(1) Use pinion gear adjustment gauge set and con­
tinue the assembly: • 8 3/8, use C-3715-B (Fig. 20)
• 9 1/4, use C-758-D6 (Fig. 21) (2) Install front (outer) bearing cup use Installer
D-130 and Handle C-4171. (3) Install rear (inner) bearing cup.
• 8 3/8 axles, use Installer C-4308 and Handle C-4171
• 9 1/4 axles, use Installer C-4310 and Handle C-4171 8 3/8 axles assemble C-3715-B Tool Set as de­
scribed (Fig. 20);
SPECIAL
TOOL
SET

G3715-B

SP-6030

SP-536—
SP-531
J9203-51

Fig.
20 8 3/8 Axle
Pinion
Adjustment Tools
• Position Spacer (SP-6030) over Shaft (SP-5385) • Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-5382)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193) 9 1/4 axles assemble C-758-D6 Tool Set as de­
scribed (Fig. 21);
SPECIAL TOOL C-758-D6
SP-6018

SP-536-*- Fig.
21 9 1/4 Axle
Pinion
Adjustment Tools and • Position Spacer (SP-6017) over Shaft (SP-526)
• Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-1730)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-535-A), Washer (SP-534)
Nut (SP-533) (4) Prevent compression sleeve tool from turning
with Wrench C-3281.
Tighten the nut to seat the pinion bearings in the
housing (Fig. 22). Allow the sleeve to turn several
times during the tightening to prevent brinelling the
bearing cups or the bearings.
Depth shim(s) are positioned between the pin­
ion gear rear bearing and pinion gear to provide the separation distance. The required thickness
of the depth shim(s) is determined according to
the following information. (5) Loosen the compression nut tool. Lubricate the
pinion gear front and rear bearings with gear lubri­ cant. Re-tighten the compression nut tool to 1-3 N*m (15-25 in. lbs.) torque. Rotate the pinion gear several
complete revolutions to align the bearing rollers. (6) Install Gauge Block.
• 8 3/8 axles (Fig. 20)
• Install Gauge Block SP-5383 at the end of SP-5385
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531 • 9 1/4 axles (Fig. 21)

•

REAR SUSPENSION
AND
AXLE
3 - 21

Fig.
22 Seating Pinion
Bearings
• Install Gauge Block SP-6020 at the end of SP-526
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531
(7) Position Crossbore Arbor in the differential
housing.
• 8 3/8 (Fig. 20); (SP-6029)
• 9 1/4 (Fig. 21); (SP-6018)
(8) Center the tool. Place a piece of 0.002 inch
shim stock at each end of the arbor. Position the
bearing caps on the arbor tool. Install the attaching

bolts.
Tighten the cap bolts to 14 N*m (10 ft. lbs.) torque.
(9) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 23). The depth shim(s)
fit must be snug but not tight (drag friction of a
feeler gauge blade).
SPACER

BEARING
CAP
ARBOR
J9203-53 Fig.
23 Depth
Shim(s)
Selection Depth shims are available in 0.001-inch incre­
ments from 0.020 inch to 0.038 inch. (10) Note the etched number on the face of the
drive pinion gear (e.g., -0, -1, -2, +1, +2, etc.). The
numbers represent thousands-of-an-inch deviation
from the standard. If the number is - (negative), add
that value to the required thickness of the depth shim(s). If the number is + (positive), subtract that
value from the thickness of the depth shim(s). If the
number is 0, no change is necessary.
(11) Remove the tools from the differential hous­
ing. (12) Position the depth shim(s) on the pinion gear.
Install the rear bearing (Fig. 24). Be sure the contact surfaces are clean and without foreign particles.
• 8 3/8 axles use Installer C-4040
PINION GEAR DEPTH
VARIANCE
Original Pinion

Gear
Depth Variance
Replacement
Pinion Gear Depth Variance

Original Pinion

Gear
Depth Variance
-4

-3
-2
-1

0
+
1

+2

+3 +4
+4
+0.008
+
0.007
+
0.006
+
0.005
+
0.004
+
0.003
+
0.002

+
0.001

0
+3
+
0.007
+
0.006

+
0.005 +0.004
+0.003
+
0.002

+
0.001

0
-0.001
+2
+
0.006
+
0.005

+
0.004

+
0.003 +0.002

+
0.001
0
-0.001
-0.002

+ 1
+
0.005
+
0.004

+
0.003 +0.002
+
0.001
0

-0.001 -0.002
-0.003

0
+0.004

+
0.003
+
0.002

+
0.001
0
-0.001
-0.002 -0.003
-0.004
-1
+
0.003
+
0.002
+
0.001
0
-0001 -0.002 -0.003 -0.004
-0.005
-2
+
0.002
+
0,001
0

-0.001 -0.002
-0.003 -0.004
-0.005 -0.006

-3
+
0.001
0
-0.001 -0.002
-0.003 -0.004 -0.005 -0.006

-0.007

-4
0 -
0.001 -0.002
-0.003 -0.004
-0.005 -0,006

-0.007
-0.008
J8902-46

3
- 22
REAR
SUSPENSION
AND
AXLE

• 9 1/4 axles use Installer C-3095

Fig.
24 Shaft Rear Bearing
Installation
(13) Lubricate the pinion gear front and rear bear­
ings with gear lubricant.
(14) Install the pinion gear in the housing. Install
the new collapsible spacer at the end of the pinion gear. Install the pinion gear front bearing.
(15) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281 (Fig. 23).
It is necessary to use the tools (above) to cor­
rectly seat the front bearing on the drive pinion gear shaft (Fig. 25).

CAUTION:
Use
care
to
prevent collapsing preload

collapsible
spacer during installation
of the
yoke

and
seating
the
front bearing.

(16) Remove yoke and tools from the pinion gear.
(17) Install the new pinion gear shaft seal (Fig.

26).

• 8 3/8-inch diameter use Seal Installer C-4076-A and Handle C-4735-1
• 9
1/4-inch
diameter use Seal Installer C-3980-A or C-4109-A and Handle C-4735 The seal is correctly installed when the seal
flange contacts the face of the differential hous­
ing flange.
The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of sealant is not required. (18) Install the pinion yoke with Remover/Installer
C-3718 and Wrench C-3281.
(19) Remove the tools. Install the Belleville
washer. The convex side of the washer must face out­ ward. Install the pinion nut. 4

J9103-21

Fig.
25
Pinion
Yoke
Installation

Fig.
26
Pinion
Gear
Seal
Installation
(20) Retain pinion yoke with Wrench C-3281. Ini­
tially tighten the drive pinion gear shaft nut enough
to remove the bearing end play. While tightening, ro­
tate the pinion shaft to ensure the bearing rollers are correctly seated. (21) Tighten the pinion nut to (Fig. 27) 285 N*m
(210 ft. lbs.) torque (minimum). (22) Remove the tools from the shaft. Rotate the
pinion several complete revolutions (both directions)
to additionally seat the bearing rollers.

CAUTION:
Never loosen
the
pinion gear
nut to de­

crease
the
pinion gear bearing preload torque.
If the

specified preload torque
is
exceeded,
a
replacement

collapsible
spacer must
be
installed.
The
torque
se­

quence
will
have
to be
repeated.
SPECIAL
DIFFERENTIAL

TOOL
HOUSING

•

REAR SUSPENSION
AND
AXLE
3 - 23
Fig. 27 Tightening Pinion Gear Nut (23) Measure the pinion bearing preload torque by
rotating pinion shaft with a Newton-meter or an inch-pound torque wrench. The correct bearing pre­load torque is 2-4 N-m (20-30 in. lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a minimum of 285 N-m (210 ft. lbs.)
torque (Fig. 28).
When using original pinion rear bearing and a
replacement front bearing. The correct preload torque is 1 N-m (10 in. lbs.) torque in addition to
the torque measured and recorded during disas­ sembly. Fig. 28 Bearing Preload Torque Measurement
The bearing preload torque should be constant
during a complete revolution of the drive pinion
gear shaft. If the preload torque varies during rotation of the shaft, there is an internal binding
that must be corrected before final assembly.
(24) If the specified torque is not obtained, tighten
the nut in small increments until the preload torque is obtained.
The differential will be unacceptable for use if
the final nut torque is less than 285 N-m (210 ft.
lbs.) torque. If the preload torque is not within the specified range this is also unacceptable.
DIFFERENTIAL CASE INSTALLATION (1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups and threaded ad­
justers. A dab of grease can be used to keep the ad­
justers in position. Carefully position the assembled differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations (Fig. 29).
Fig.
29 Bearing
Caps
&
Bolts

(3) Install the bearing cap bolts (Fig. 29). Tighten
the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten the lower bolts finger-tight until the bolt head is lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING GEAR BACKLASH ADJUSTMENT The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed dur­
ing all backlash measurements
• Maintain the torque while adjusting the bearing
preload and ring gear backlash • Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise