Bearing DODGE TRUCK 1993 Service Owner's Manual

2
- 24
FRONT SUSPENSION
AND
AXLE

ASSEMBLY
(1) Insert the needle bearing and cap in one yoke
arm bore. (2) Place the yoke in a vise (Fig. 21) and press the
needle bearing and cap into position. Install the snap
ring.

Fig.
21 Bearing Cap
installation

(3) Remove the yoke from the vise and insert one
end of the spider into the bearing. Insert opposite
bearing and cap in the yoke arm bore by hand and align it with the spider.
(4) Place the yoke in a vise and press the cap into
the yoke arm bore and onto the spider (Fig. 22). YOKE

RH403

Fig.
22 Bearing Cap &
Spider
Installation
(5) Use a short plug or a socket wrench to force the
bearing cap into the correct position and install the snap ring.
(6) Repeat the instructions in steps 1 through 5 for
installing remaining bearings, caps and yoke.
STEERING
KNUCKLE, UPPER
AID
LOWER BALL STUDS

REMOVAL/DISASSEMBLY (1) Remove axle shaft, refer to Hub, Spindle and
Axle Shaft Removal.
(2) Disconnect the tie-rod end from the steering
knuckle arm. (3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts (Fig.
23).
Discard the lower nut.
WRENCH
STEERING KNUCKLE

J9202-83

Fig.
23 Upper
Ball
Stud
Nut
Removal
(4) Separate the steering knuckle from the tube
with a soft hammer (Fig. 24).
RAWHIDE

HAMMER
UPPER
BALL
STUD

STEERING KNUCKLE

J9202-84

Fig.
24 Steering
Knuckle
Removal

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.

•

FRONT SUSPENSION
AND
AXLE
2 - 31
Fig. 35 Disconnect Axle Service Tools ASSEMBLY/INSTALLATION
(1) Install the needle bearing in the end of the in­
termediate shaft with Installer D-328 and Driver Handle C-4171 (Fig. 36).
RK
727
Fig. 36 Intermediate Shaft Bearing installation (2) Install the intermediate axle shaft bearing with
Tool D-354-4, Tool 354-2 and Slide Hammer C-637 (Fig. 34, 35).
(3) Install the intermediate axle shaft with Tool
D-354-4 and Adaptor Tool D-354-3.
(4) Install the C-lock in the axle shaft and side
gear.
(5) Clean the tube bore and remove any rust from
the seal area.
(6) Place the axle shaft seal on Tool 5041-1 and po­
sition in housing. Thread Tool 5041-2 through the
seal into Tool
5041-1.
Install Tool 5041-3 and nut on
the end of the threaded bar tool. Tighten the nut un­
til the tool contacts the threaded bar shoulder.
(7) Install the shift collar on the splined end of the
intermediate axle shaft.
(8) Lubricate the splined end of the intermediate
axle shaft with multi-purpose lubricant.
(9) Install the axle shaft, spindle and hub, refer to
the installation procedures above. (10) Install the shift motor housing, refer to Vac­
uum Shift Motor Installation.
STEERING
KNUCKLE
ARM

REMOVAL
(1) Install Puller C-4150 on each drag-link ball
stud. Apply sufficient force with the tool to loosen
the drag-link ball stud from the steering arm.
(2) Remove the lock nuts that attach the steering
arm to the knuckle (Fig. 37). Tap the steering arm to
loosen it from the knuckle. Pry upward to remove. Fig. 37 Steering Knuckle Arm Removal

INSTALLATION

(1) Position the steering arm on the knuckle. In­
stall the nuts. Tighten the nuts to 122 N«m (90 ft.

lbs.).

(2) Position the drag link at steering knuckle arm.
(3) Install and tighten the ball stud nut to 81 N*m
(60 ft. lbs.) torque. Install new cotter pins.

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) Remove the front wheels/tires.
(2) Mark the front drive shaft and the pinion yoke
for installation alignment reference.
(3) Disconnect the front drive shaft from the axle
yoke. Attach the drive shaft to the frame rail with

wire.

(4) Remove the cotter pin, nut, and disconnect the
drag link from the steering knuckle arm (left side

only).
Discard the cotter pin.

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.

•

FRONT
SUSPENSION
AND
AXLE
2 - 33 (9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
bolts.
Tap the ring gear with a rawhide mallet and
remove (Fig. 40).

RING
GEAR SPECIAL
TOOL

C-3281

SPECIAL
TOOL
C-452
J9102-31
RAWHIDE

HAMMER

J9202-76
Fig.
40
Ring
Gear
Removal

(10) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 41). (11) Use Remover C-748 to remove the pinion gear
seal.
(12) Remove oil slinger, front bearing and shims
(Fig. 42). Record the thickness of the shims. This will
Fig.
41
Pinion
Yoke
Removal

save time if they should become misplaced.
(13) Remove the front pinion bearing cup with Re­
mover D-158 and Handle C-4171 (Fig. 43). (14) Remove the rear bearing cup from housing
(Fig. 44). Use Remover D-162 and Handle C-4171.
(15) Remove the depth shims from the housing
bore. Record the thickness of the depth shims.
(16) Remove the inner bearing from the pinion
with Puller C-293-PA and Plate C-293-39 (Fig. 45).

PINION
YOKE WASHER
SLINGER

PINION

PRELOAD SHIMS
FRONT

BEARING CUP

PINION
PRELOAD
SPACER
PINION
NUT
PINION
OIL
SEAL

FRONT

BEARING CONE
SHOULDER
FOR

•
PINION
PRELOAD SPACER
J9203-63
Fig.
42
Pinion
Front Bearing and Preload
Shims

2
- 34
FRONT SUSPENSION
AND
AXLE

•

SPECIAL
TOOL
SPECIAL
TOOL
D-158
C-4171
Fig.
44 Rear Bearing Cup Removal (17) Clamp the differential case in a vise equipped
with soft jaws. Use a pin punch to remove the pinion gear mate shaft lock pin (Fig, 46).
(18) Remove the mate shaft with a drift and ham­
mer (Fig. 47).
(19) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 48).
(20) Remove the differential side gears and thrust
washers. (21) Remove the case from the vise.
SPECIAL

TOOL

C-293-PA

Fig.
46
Mate
Shaft
Lock
Pin
Removal
(22) Remove the bearings from the differential
case with Press C-293-PA, Plug C-293-3, Plate C-293-18 and a vise (Fig. 49).
Use care that adapter rings are placed so they
do not damage the bearing cage.
(23) Remove bearing shims from case hubs and
mark them (with hub identity) for assembly refer­

ence.
Record the thickness of the shims.
CLEANING/INSPECTION (1) Wash and clean all the differential components
with cleaning solvent. Dry with compressed air.
Do not steam clean the differential compo­

nents.

(2) Clean the axle shaft tubes. Insert a stiff wire
into each tube, attach a clean cloth to the wire at the

•

FRONT
SUSPENSION
AND
AXLE
2 - 35

PINION
MATE SHAFT ADAPTERS

DRIFT
J9203-60

Fig.
47
Mate
Shaft
Removal
THRUST

WASHER

PINION

MATE GEAR SIDE GEAR
J9203-61

Fig.
48
Pinion
Mate
Gear
Removal

housing opening. Draw the wire (and cloth) from the
housing outward through the tube. (3) Inspect the differential and pinion gear bearings.
Inspect the differential case and housing.
• Bearings and cups should have a smooth appear­
ance.

• Bearing races must not be distorted or cracked Cup and bearing must be replaced as a
matched set only. • All machined surfaces in the housing and on bearing
caps should be smooth and without any raised edges.
• Pinion gear front and rear bearing cup bores should be smooth
• Raised metal on shoulders of cup bores should be
removed with a hand stone
PLUG
SPECIAL

TOOL

C-293-PA

J9202-42

Fig.
49
Differential
Bearing
Removal
(4) Examine the differential pinion mate shaft,
pinion gears, side gears and thrust washers for wear and damage. Replace all defective components.
If either of the differential pinion gears is not
reusable, both gears must be replaced as a matched set only. Do not replace only one gear.
(5) Examine the ring gear and the pinion gear for
worn and chipped teeth. Examine the ring gear for damaged bolt threads.
If replacement of either gear is necessary, both
must be replaced as a matched set only.
(6) Inspect the pinion yoke for cracks, worn
splines, pitted areas, and a rough/corroded seal con­
tact surface. Repair or replace the yoke as necessary.
(7) Inspect the pinion bearing preload shims for
cracks, damage and distortion. Install replacement shims (if necessary) for the preload torque adjust­
ment.

DIFFERENTIAL
ASSEMBLY

ASSEMBLY (1) Install the following components in the differ­
ential case.
• Differential side gears and thrust washers
• Pinion gears and thrust washers

2
- 36
FRONT
SUSPENSION
AND
AXLE

• • Pinion gear mate shaft (align holes in shaft and
case) (2) Install and seat the lock pin in the differential
case and mate shaft with a punch and hammer (Fig.
50).
Peen metal part of case over pin in two places.
If replacement gears and thrust washers were
installed, it is not necessary to measure the gear
backlash. Correct fit is due to close machining
tolerances during manufacture.

Fig.
50
Mate
Shaft Pin
installation

(3) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment (Fig. 51).
(4) Install new ring gear bolts and alternately
tighten to 61-81 N*m (45-60 ft. lbs.) torque.
(5) Lubricate all differential components with hy­
poid gear lubricant.
(6) Place Master Differential Bearing D-345
(D-135) on the case hubs (Fig. 52).
(7) Install a pilot stud at the right side of housing.
Attach Dial Indicator C-3339 to the pilot stud. Load
indicator plunger against the back of the ring gear (Fig. 53).
(8) Insert a small pry bar between the bearing cap
and left side of differential case. Pry the case as far as possible to right side (Fig. 53). Zero the dial indi­
cator pointer.
(9) Pry the case to left side and record the travel
distance. The measurement above is the shim thickness
necessary for case zero end-play. The total
thickness will be determined during the ring gear backlash adjustment. (10) Remove indicator and pilot stud.
TORQUE

Fig.
51
Ring
Gear
Bolt
Hole
Installation
SPECIAL
TOOL

D-345

J9203-20

Fig.
52 Master Bearing Tools On
Hubs

PINION GEAR DEPTH INFORMATION Gears are supplied as matched sets only. The iden­
tifying numbers for the ring and pinion gear are etched into the face of each gear (Fig. 54). A plus
(
+ )
number, minus (-) number or zero (0) is etched into
the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best tooth contact pattern.

•

Fig,
53
Differential
Case
End Play Measurement
DRIVE
PINION

Fig.
54
Pinion
Gear ID
Numbers
The standard depth is the distance (Fig. 55) from
the centerline of the axle shaft/ring gear to the shoulder of the rear pinion bearing.
Compensation for depth variance is achieved by
shims placed adjacent to the pinion gear rear bearing
cup (Fig. 56).
If a new gear set is being installed, note the depth
variance etched into the original and new pinion
gear. Add or subtract the thickness of the original
depth shims to compensate for the difference in the
depth variances. Refer to the Depth Variance charts.
For Example:
• If a positive marking, this means the shim pack
must decrease by the same number of thousandths. • If a negative marking, this means the shim pack
must increase by the same number of thousandths.
FRONT
SUSPENSION
AND
AXLE
2 - 37

Fig.
55
Pinion
Gear Standard Depth/Distance
DRIVE

Fig.
56
Shim
Locations
• If marked zero will use the nominal setting as de­
termined in this procedure.
Shims are available in 0.003-inch, 0.005-inch,
0.010-inch, and 0.030-inch thicknesses.
If original gear set is installed but the depth shims
replaced, measure the thickness of the original depth shims. Build a replacement pack of depth shims with
the same thickness.
If equipped, the oil slinger must be measured
and the thickness included with the total shim
pack thickness.
The shim thickness for the new pinion gear must
be determined before installing the differential case.
AXLE
DEPTH

MODEL
SETTING

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.