tow DODGE TRUCK 1993 Service User Guide

•

FRONT
SUSPENSION
AND
AXLE
2 - 5 (4) Front wheels for excessive radial, lateral
runout and unbalance. Refer to Group 22, Wheels and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3, Suspension and Axle for additional information.

WHEEL
ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
the specified limits. This will prevent abnormal tire
tread wear. The equipment manufacturer's recommenda­
tions for use of their
equipment
should always
be followed. All
damaged
front suspension sys­
tem components
should
be replaced. Do not at­ tempt to straighten any
bent
component.

CAMBER AND CASTER-2WD VEHICLES Camber and caster angle adjustments involve repo­
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom­
plished by loosening the nuts and changing the posi­
tion of the cam bolt.
(1) Remove all foreign material from the adjust­
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the Specifications chart.
CAMBER AND CASTER—4WD VEHICLES For 4WD vehicles, the correct wheel camber (verti­
cal tilt) angle is factory preset at zero degree (0°).
Camber cannot be altered by adjustment.
CAUTION: Do not attempt to
adjust
the
camber
an­
gle by
heating
or bending the axle or any
suspen­

sion
component. If camber angle is
incorrect,
the
component(s)
causing
an
incorrect
angle must be replaced.
(1) It is important that the camber (vertical tilt)
angle be the same for both front wheels.
(2) The camber angle should be measured with ac­
curate wheel alignment equipment. The acceptable
range is -1° to +1°. Refer to the Specifications chart.
Road test the vehicle and observe the steering
wheel return-to-center position. Before road testing,
check
and
correct
the tire
inflation pressures. Inflate
both
of the front tires
with exactly the
same
pressure.
During the road test, make vehicle turns to both
the left and right. If the steering wheel returns to­
ward the center position unassisted, the caster angle is correct. However, if the steering wheel does not re­ turn toward the center position unassisted, an incor­
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees
(
+
2°).
The acceptable range is +1/2° to +
3
1/2°.
(2) The caster angle should be measured with ac­
curate wheel alignment equipment.
(3) Caster angle can be adjusted by installing ta­
pered shims between the front axle pads and the spring brackets. The caster angle should be adjusted
as near as possible to the preferred angle.
(4) Record the caster measurement before remov­
ing the original shims from the spring pads.
(5) The caster should be the same at both sides of
the vehicle. Refer to the Specifications chart.
RN1030

Fig.
2 Caster &
Camber
Adjustment Location—2WD
Vehicles

WHEEL TOE POSITION The wheel toe position adjustment should be the fi­
nal front wheel alignment adjustment. In all in­ stances, follow the equipment manufacturer's
recommended procedure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight­ ening the wheels.
With power steering, the engine should be op­
erating during the wheel toe position adjust­
ment.
(2) Loosen the tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust the wheel toe position by rotating the
tie rod adjustment sleeve (Fig. 3). Rotate each tie-rod end in the direction of
sleeve rotation during the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the center of their travel.
(4) If applicable, turn the ignition switch off.

2
- 30
FRONT
SUSPENSION
AND
AXLE

• REMOVAUDISASSEMBL
Y

(1) Raise and support the vehicle.
(2) Disconnect the vacuum and wiring connector
from the shift housing. (3) Remove the shift motor housing cover, gasket
and shield from the housing.
(4) Remove the E-clips from the shift motor hous­
ing and shaft. Remove shift motor and shift fork
from the housing (Fig. 32).
Fig.
32
Vacuum
Shift Motor
Components

(5) Remove the O-ring seal from the shift motor
shaft. (6) Clean and inspect all the components. If any
component is excessively worn or damaged, it should
be replaced.
ASSEMBL Y/IHSTALLA TION (1) Install a replacement O-ring seal on the shift
motor shaft (Fig. 32). (2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset should be toward the differential.
(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover. Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and bolts.
Tighten the bolts to 14 N*m (10 ft. lbs.) torque.

INTERMEDIATE AXLE SHAFT
REMOVAL/DISASSEMBLY (1) Remove the vacuum motor housing from the

axle,
refer to Vacuum Shift Motor Removal.
(2) Remove the hub, spindle and axle shaft, refer
to the removal procedures above.
(3) Remove the shift collar from the shift motor
housing.
(4) Remove the differential housing cover and
drain the lubricant.
(5) Push the intermediate axle shaft toward the center of the vehicle. Remove the C-lock from the
shaft and side gear in the differential.
(6) Remove the intermediate axle shaft with Re­
mover/Installer D-354-4 and Adaptor D-354-3 (Fig.

33).

J9202-104
Fig.
33
intermediate
Axle Shaft Removal/Installation
(7) Remove the intermediate axle shaft bearing
with Tool D-354-4, Tool
D-354-1,
and Slide Hammer C-637 (Fig. 34, 35).
(8) Remove the needle bearing from intermediate
axle shaft with Remover/Installer D-330 (Fig. 34, 35).

RK724

Fig.
34
Intermediate
Shaft Bearing
Removal

(9) Remove the inner axle shaft seal from the shift
motor housing. Certain vehicles could also have a
seal guard; discard both components. The guard is
not used with a replacement seal.

2
- 32
FRONT
SUSPENSION
AND
AXLE

• (5) Disconnect flexible brake fluid hose fittings at
the frame crossmember. Plug the hoses at the fit­

tings.

(6) Remove the shock absorber lower nut and stud
from the axle shaft tube bracket. Remove the nuts and disconnect the stabilizer bar links from the
spring brackets.
(7) Disconnect the vacuum hoses and wiring con­
nections from the shift motor housing.
(8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve­
hicle.

INSTALLATION
(1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group. (3) Install the shock absorber. Refer to Front Sus­
pension — 4WD Vehicles within this group. (4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension-4WD Vehicles
within this group.
(5) Remove plugs and connect the brake hose fit­

tings.
Refer to Group 5, Brakes. (6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering. (7) Connect the drive shaft to the pinion yoke with
the installation reference marks aligned. Install the
washers and the nuts and tighten to 19 N*m (14 ft. lbs.) torque.
(8) Connect the vacuum hoses and wiring connec­
tions to the shift motor housing. (9) Remove the supports, lower the vehicle and re­
move the block from the brake pedal.
(10) Raise the vehicle.
• Bleed and adjust the brakes
• Lubricate all the ball stud fittings
• Inspect the differential housing lubricant level. Re­
fer to Group 0, Lubrication and Maintenance. (11) Lower the vehicle and test the axle and sus­
pension operation.

DIFFERENTIAL
DISASSEMBLY

REMOVAL/DISASSEMBLY (1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 38). (2) Remove the differential bearing caps.
(3) Position Spreader W-129-A with the tool dowel
pins seated in the locating holes (Fig. 39). Install the
holddown clamps and tighten the tool turnbuckle fin­ ger-tight.
INSTALLATION

EFERENCE
LETTERS

J9003-92

Fig.
38 Bearing Cap
Identification
SPECIAL
TOOL

MODEL
44-W-129-A
MODEL
60-D-167
DIAL

INDICATOR

«ar"P—

J9202-113

Fig.
39
Differential
Housing
Separation
(4) Install a pilot stud at the left side of the differ­
ential housing. Attach Dial Indicator to housing pilot stud. Load the indicator plunger against the opposite
side of the housing (Fig. 39) and zero the indicator.

CAUTION:
Do not
spread
over the specified
dis­

tance.
If the
housing
is over-separated, it
could
be distorted or
damaged.

(5) Separate the housing enough to remove the
case from the housing. Separate housing a maxi­
mum distance of 0.38 mm (0.015 in) with the spreader tool. Measure the distance with the dial
indicator (Fig. 39).
(6) Remove the dial indicator.
(7) Pry the differential case loose from the hous­
ing. To prevent damage, pivot on housing with the end of the pry bar against case.
(8) Remove the case from housing. If they are re­
usable, retain the differential bearing cups and bear­ ings together as matched sets.

2
- 38
FRONT
SUSPENSION
AND
AXLE

•
PINION GEAR DEPTH VARIANCE

Or§@ift^i
Linton
IsptocMnwtt
HnS®n
Oior Itoplli
fflttanct

Or§@ift^i
Linton
-4
-2

-1
0

+
1

-ft
+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
-0.001
-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
PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH TOOL SET D-11144
The following gear depth measurement and adjust­
ment procedure involves using Tool Set D-115-44. (1) Insert Master Pinion Block D-139 into the
dif­

ferential housing (Fig. 57).

PINION BLOCK TOOL PINION BLOCK TOOL
J8902-46

DIFFERENTIAL
HOUSING

ARBOR
DISC
TOOL
ARBOR

TOOL
J9003-103
DIFFERENTIAL

HOUSING
J9003-101
Fig.
57
Pinion
Block
In Shaft
Bore

(2) Place Disc D-115-4 on Arbor D-115-3 and posi­
tion in the bearing cradles (Fig. 58). This is the cen­
terline of the ring gear/axle shaft. (3) Place Pinion Height Block D-115-1 on top of
master pinion block tool and against arbor tool (Fig.
59).

(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step of block tool (Fig. 60). Zero
the dial indicator pointer.
Fig.
58
Disc
&
Arbor
In
Housing

(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
60).
Slide the gauge block across the arbor while ob­
serving indicator. Record the longest travel distance,
whether inward (-) or outward (+•), indicated by the
pointer.
The distance indicated, plus or minus the
amount etched in the gear is the required thick­

ness.

(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim pack thickness if
required.
(7) Remove the measurement tools from the differ­
ential housing.

FRONT
SUSPENSION
AND AXLE
2 - 47

DRIVE
SIDE
OF RING

GEAR
TEETH
HEEL

TOE
COAST
SIDE
OF RING

GEAR
TEETH TOE

HEEL
DESIRABLE
CONTACT PATTERN.
PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH. PATTERN SHOULD BE CENTERED
ON

THE COAST SIDE OF TOOTH, BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE
SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP
OF

THE TOOTH.
RING GEAR
BACKLASH
CORRECT

THINNER
PINION GEAR DEPTH SHIM REQUIRED.
RING GEAR
BACKLASH
CORRECT.

THICKER
PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT
DECREASE
RING

GEAR
BACKLASH.

PINION GEAR DEPTH SHIM

CORRECT
INCREASE
RING

GEAR
BACKLASH.

Fig.
86 Gear
Teeth
Contact Patterns
J9003-24

•

TAPERED

BUSHING

J9202-53

Fig.
32 Tapered
Bushing
Installation

J9202-52

Fig.
33
Lower
King
Pin and Retainer
Installation
(12) Install the axle shaft, refer to Axle Shaft and
U-Joint Installation.

COMPLETE
AXLE REMOVAL/INSTALLATION SERVICE
INFORMATION
It is not necessary to remove the complete front
axle from the vehicle for routine service. If the hous­
ing or axle shaft tubes are damaged, the complete axle can be removed and installed via the following
procedures.

REMOVAL
(1) Block the brake pedal in the up position. Raise
and support the vehicle at a comfortable working
height.
(2) Remove the front wheels/tires.
FRONT SUSPENSION
AND
AXLE
2 - 59
(3) Mark the front drive shaft and the pinion yoke
for installation alignment reference.
(4) Disconnect the front drive shaft from the axle
yoke. Attach the drive shaft to the frame rail with
wire.

(5) Remove the cotter pin, the nut, and disconnect
the drag link from the steering knuckle arm (left side only). Discard the cotter pin.
(6) Disconnect flexible brake fluid hose fittings at
the frame crossmember. Plug the hoses at the fit­

tings.
(7) Remove the shock absorber lower nut and stud
from the axle shaft tube bracket. Remove the nuts and disconnect the stabilizer bar links from the
spring brackets. (8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve­
hicle.
INSTALLATION (1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group. (3) Install the shock absorber. Refer to Front Sus­
pension—4 WD Vehicles within this group.
(4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension—4WD Vehicles within this group.
(5) Remove plugs and connect the brake hose fit­

tings.
Refer to Group 5, Brakes. (6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering. (7) Connect the drive shaft to the pinion yoke with
the installation reference marks aligned. Install the
washers and the nuts and tighten to 19 N-m (14 ft. lbs.) torque.
(8) Remove the supports, lower the vehicle and re­
move the block from the brake pedal.
(9) Raise the vehicle.
• Bleed and adjust the brakes
• Lubricate all the ball stud fittings
• Inspect the differential housing lubricant level. Re­
fer to Group 0, Lubrication and Maintenance.
(10) Lower the vehicle and test the axle and sus­
pension operation.

DIFFERENTIAL DISASSEMBLY
REMOVAL/DISASSEMBLY
(1) Note the installation reference letters
stamped on the bearing caps and housing ma­
chined sealing surface (Fig. 34).
(2) Remove the differential bearing caps.

2
- 66
FRONT
SUSPENSION
AND
AXLE

•
PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH
TOOL
SET
D-116 The following gear depth measurement and adjust­
ment procedure involves using Tool Set D-116. (1) Insert Master Pinion Block D-120 into the
dif­

ferential housing (Fig. 53).

Fig.
53
Pinion
Block
In Shaft
Bore

(2) Place Disc D-116-2 on Arbor D-115-3 and posi­
tion in the bearing cradles (Fig. 54). This is the cen­
terline of the ring gear/axle shaft.

Fig.
54
Disc
&
Arbor
In
Housing

(3) Place Pinion Height Block D-116-1 on top of
master pinion block tool and against arbor tool (Fig.

55).

(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step (Fig. 56). Zero the dial indi­
cator pointer.
(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
56).
Slide the gauge block across the arbor while ob­
serving indicator. Record the longest travel distance,
whether inward (-) or outward
(
+ ), indicated by the
pointer.
Fig.
55
Pinion
Height
Block
Against
Arbor

Fig.
56
Pinion
Gear Depth Measurement
Plunger travel distance indicated, plus or mi­
nus the amount etched in gear is required thick­

ness.

(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim pack thickness.
(7) Remove the measurement tools from the differ­
ential housing.
(8) Place the depth shims in the pinion gear rear
bearing bore. Install the bearing cup (Fig. 57) with
Installer D-lll and Handle C-4171.
Ensure the cup is correctly seated. (9) Install the pinion front bearing cup with In­
staller C-4203 and Handle C-4171 (Fig. 58). (10) Install the rear bearing (and slinger if used)
on the pinion gear with Installer C-3095-A until
completely seated (Fig. 59).
(11) Assemble preload shims onto pinion and in­
stall the pinion gear in housing.

2
- 74
FRONT SUSPENSION AND AXLE

DRIVE
SIDE
OF RING

GEAR
TEETH
HEEL

TOE
COAST
SIDE
OF RING

GEAR
TEETH TOE

HEEL
DESIRABLE
CONTACT PATTERN.
PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH.
PATTERN SHOULD BE CENTERED
ON

THE COAST
SIDE
OF TOOTH, BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE
SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP
OF

THE TOOTH.
RING GEAR
BACKLASH
CORRECT.

THINNER
PINION GEAR DEPTH
SHIM REQUIRED.
RING GEAR
BACKLASH
CORRECT.

THICKER
PINION GEAR DEPTH SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT
DECREASE
RING

GEAR
BACKLASH.

PINION GEAR DEPTH SHIM

CORRECT
INCREASE
RING

GEAR
BACKLASH.

Fig.
83 Gear Teeth Contact Patterns
J9003-24

3
- 6
REAR SUSPENSION
AND
AXLE

•

NUT PIPE
SOCKET
WRENCH
(DRIVER)

FLAT
THREADED
WASHER
ROD
J8917-20

Fig.
6
Spring
Eye
Bushing
Removal
(3) Align
the
bushing with
the
spring
eye and

tighten
the nut
located
at the
socket wrench
end of

the threaded
rod.
Tighten until
the
bushing
is
forced into
the
spring
eye.

The bushing must
be
centered
in the
spring

eye.
The
ends
of the
bushing must
be
flush
or
slightly recessed within
the end
surfaces
of the

spring
eye.
8ERW1GE DIAGNOSIS
INDEX
page

Driveline
Snap
8

Gear
and
Bearing Noise
7

General
Information
6
Limited
Slip
Differential
8
page
Low Speed Knock
.........................
8
Rear
Axle
Alignment
.......................
7

Tire
Noise
7
Vibration
8

GENERAL INFORMATION
Axle bearing problem conditions
are
usually caused
by: • Insufficient
or
incorrect lubricant
• Foreign matter/water contamination
• Incorrect bearing preload torque adjustment When serviced,
the
bearings must
be
cleaned thor­
oughly. They should
be
dried with lint-free shop tow­

els.
Never
dry
bearings with compressed
air.

This will overheat them
and
brinell
the
bearing surfaces. This will result
in
noisy operation after
repair. Axle gear problem conditions
are
usually
the
result

of:

• Insufficient lubrication
• Incorrect
or
contaminated lubricant
• Overloading (excessive engine torque)
• Incorrect clearance
or
backlash adjustment Insufficient lubrication
is
usually
the
result
of a

housing cover leak.
It can
also
be
from worn axle shaft
or
pinion gear seals. Check
for
cracks
or
porous
areas
in the
housing
or
tubes.
Using
the
wrong lubricant will cause overheating
and gear failure. Gear tooth cracking
and
bearing
spalling
are
indicators
of
this.
Axle component breakage
is
most often
the
result

of:

• Severe overloading
• Insufficient lubricant
• Incorrect lubricant • Improperly tightened components
Common causes
of
overloading
is
from full-throttle
acceleration. Overloading occurs when towing
heavier than normal loads. Component breakage
can
occur when
the
wheels
are
spun excessively. Insuffi­
cient
or
incorrect lubricants contribute
to
breakage
through overheating. Loose differential components can also cause breakage. Incorrect bearing preload
or
gear backlash will
not

result
in
component breakage. Mis-adjustment will
produce enough noise
to
cause service repair before
a

•

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)