torque DODGE TRUCK 1993 Service Service Manual

2
- 54
FRONT SUSPENSION
AND
AXLE
Fig.
12 Spindle Removal
SEAL
J9202-73

Fig.
13 Axle Shaft Removal

Fig.
14
Spindle
Needle Bearing
Removal

(2) Install a new spindle seal with Installer C-4373
and Handle C-4171 (Fig. 16).
(3) Install the seal with lip facing the axle shaft
splines (Fig. 17). Lubricate the seal (Fig. 18) with
Wheel Bearing Grease lubricant (NLGI Grade 2, EP
or an equivalent lubricant). •

Fig.
15
Spindle
Needle Bearing
Installation
Fig.
16
Spindle
Seal
Installation

(4) Carefully install the axle shaft through the
knuckle into the axle housing. Ensure the axle shaft splines are engaged with the differential side gears.
(5) Install the spacer on the axle shaft end.
(6) Install the brake splash shield and brake cali­
per support bracket.
(7) Install the splash shield and spindle on the
steering knuckle. Install the nuts and tighten to 81- 108 N-m (60-80 ft. lbs.) torque (Fig. 19).

•

Fig.
17 Axle Shaft
Seal
Installation

Fig.
19
Spindle
Installation
(8) Install the hub and rotor assembly on the spin­

dle.
Add Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant) to the bear­

ings.
FRONT
SUSPENSION
AND
AXLE
2 - 51

Fig.
20 Bearing Cap
Removal
(3) Use a mallet to drive the vertical yoke down­
ward to remove the upper needle bearing and cap (Fig. 20).
(4) Reverse the position of the yoke and remove op­
posite needle bearing and cap (Fig. 20). (9) Install the wheel bearing inner lock nut on the
spindle with Wrench 7158 (Fig. 11). Tighten the lock
nut to 68 N*m (50 ft. lbs.) to seat the bearings. (10) Loosen the inner lock nut. Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rotating the hub and
rotor assembly.
(11) Back off the inner lock nut 135-150 degrees to
set the free play.
(12) Install the tabbed lock washer in the nearest
hole in the washer. Install and tighten the outer lock nut with Wrench 7158 (Fig. 11) to 217-278 N-m (160-205 ft. lbs.) torque. The end play after the final bear­
ing adjustment should be within 0.001 inch to 0.010 inch (0.03 to 0.25 mm).
(13) Install the locking body assembly in the hub.
(14) Install the lock ring in the groove in the hub.
Ensure the ring is seated. (15) Install the snap ring on the end of the axle
shaft. Ensure the snap ring is seated.
(16) Install the cap onto the hub. Ensure the seal
is in place and not distorted.
(17) Install and tighten the allen-head screws to
4-5 N-m (35-45 in. lbs.) torque.
(18) Install the brake caliper, refer to Group 5,
Brakes. (19) Install the wheel and tire, refer to Wheel and
Tire Installation within this section. Lower the vehicle.

AXLE SHAFT AND
U-JOINT
SERVICE DISASSEMBLY
(1) Remove the snap rings from the yokes.
(2) Position the U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.

•

FRONT
SUSPENSION
AND
AXLE
2 - 57

Fig.
24
Spring
and Retainer
Removal

LOWER KINGPIN
AND
RETAINER
CAP
^
J9202-51

Fig.
25
Lower
Cap
Removal

INSTALLATION (1) Apply sealant to the mating surface of the
grease retainer. Lubricate the lower ball socket with
MOPAR Multi-Mileage Lubricant (or equivalent).
(2) Install the grease retainer in the yoke bore
with the concave side facing the upper kingpin.
(3) Use Remover/Installer C-4212-L, C-4366-3, and
C-4366-4 (Fig. 29) to install a new grease seal and
lower bearing cup.
(4) Fill the area in grease retainer with specified
grease, grease bearing cone and install. Install new
king pin bearing oil seal. Reposition Tools C-4212-L,
TAPERED
BUSHING
J9202-53

Fig.
26 Tapered
Bushing
Removal
J9202-66

Fig.
27 Upper
Kingpin
Removal
C-4366-3 and C-4366-5 (Fig. 30) and press the lower
bearing cup and seal into yoke lower arm bore.
(5) Use Remover/Installer D-192 to install the up­
per kingpin (Fig. 31). Tighten the kingpin to 668-813 N-m (500-600 ft. lbs.) torque. Install the seal over the
kingpin.
(6) Install the knuckle on the axle yoke.
(7) Insert the tapered bushing over the upper king
pin (Fig. 32).
(8) Fill the socket lower cavity with MOPAR
Multi-Mileage Lubricant (or equivalent). Install the
lower king pin and retainer cap on the steering
knuckle (Fig. 33). Install the capscrews and tighten
to 95-122 N-m (70-90 ft. lbs.) torque.
(9) Install the retainer and compression spring on
the tapered bushing.

2
- 58
FRONT
SUSPENSION
AND
AXLE

•

C-4366-2
C-4366-1
RH432A
C-4212-L

Fig.
28
Lower
Ball
Socket
Removal

C-4212-L

C-4366-3
C-4366-4

RH433A

Fig.
29
Lower
Bearing Cup Installation
(10) Install a new gasket over the steering knuckle
upper studs. Install the upper cap (and steering arm
C-4212-L

C-4366-3

RH434A

Fig.
30
Lower
Bearing &
Seal
Installation
TORQUE

WRENCH

SEAL
J9202-66

Fig.
31 Upper
Kingpin
Installation
on the left side). Install the bolts/nuts and tighten to
96-122 N*m (70-90 ft. lbs.) torque. (11) Lubricate the upper and lower king pin
through the fittings with MOPAR Multi-Mileage Lu­
bricant (or equivalent).

•

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.

•

FRONT SUSPENSION
AND
AXLE
2 - 63

THRUST

WASHER

Fig.
45
Pinion
Mate
Gear
Removal
• 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 bear­
ing 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.
(4) Examine the differential pinion gear 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 (Fig. 47). • Differential side gears and thrust washers
• Pinion gears and thrust washers
• 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.

46).
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.
46
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. 47). (4) Install new ring gear bolts and alternately
tighten to;
• Grade 8 bolts to 136-163 N*m (100-120 ft. lbs.)
torque
• Grade 9 bolts (7 radial lines) to 169-183 N*m (125- 135 ft. lbs.) torque.
(5) Lubricate all differential components with hy­
poid gear lubricant. (6) Place Master Differential Bearing D-343
(D-117) on the case hubs (Fig. 48). (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. 49).
(8) Insert a small pry bar between the bearing cap
and right side of differential case. Pry the case as far
as possible to left side (Fig. 49). Zero the dial indica­
tor pointer.
(9) Pry the case to right side and record the
travel distance.

2
- 64
FRONT
SUSPENSION
AND
AXLE
—

Fig.
47 Ring Gear Bolt Hole
installation

MASTER BEARING

RY652

Fig.
48 Master Bearing Tools On
Hubs
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.
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. 50). A plus
(
+ )
number, minus (-) number or zero (0) is etched into •

Fig.
49
Differential
Case
End Play Measurement 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 teeth contact pattern.
DRIVE
PINION

Fig.
50
Pinion
Gear ID
Numbers
The standard depth is the distance (Fig. 51) from
the centerline of the axle shaft/ring gear to the shoulder of the rear pinion bearing.
• Model 60 axle, the standard depth/distance is

5.000
inches (127.0 mm).
Compensation for depth variance is achieved by
shims placed adjacent to the pinion gear rear bearing
cup (Fig. 52). 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.
TORQUE

•

FRONT
SUSPENSION
AND
AXLE
2 - 67

SPECIAL
TOOL
D-111
PRESS
DRIVE

PINION GEAR SHAFT

REAR
BEARING' INSTALLATION
TOOL
SPECIAL

TOOL

C-4171
J9203-65
DRIVE

PINION GEAR OIL

SUNGER

J9302-68

Fig.
57
Pinion
Rear Bearing Cup
Installation
Fig.
59
Pinion
Rear Bearing
Installation

BEARING
CUP
INSTALLATION TOOL
C-4203
DRIVER

HANDLE TOOL

C-4171
SPECIAL

TOOL

C-3718
DIFFERENTIAL
HOUSING

SPECIAL
TOOL

C-3281

Fig.
58
Pinion
Front Bearing Cup
Installation
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer C-3718 and Wrench C-3281 (Fig. 60).
(13) Tighten the yoke nut to 339-366 N-m (250-270
ft. lbs.) torque. (14) Check bearing preload torque with an inch
pound torque wrench (Fig. 61). The torque necessary
to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.)
• New Bearings — 2 to 5 N-m (20 to 40 in. lbs.) If the preload torque is not within the specified tol­
erance, correct the shim thickness accordingly (Fig.
62);

• Increase the preload torque, decrease the shim
thickness
J9103-21

Fig.
60
Pinion
Yoke
Installation

• Decrease the preload torque, increase the shim
thickness (15) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 63).
(16) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 64) with
Installer C-3719-A and Handle C-4735
(17) Install the yoke with Installer C-3718 and
Wrench C-3281 (Fig. 60).

2
- 88
FRONT
SUSPENSION
AND
AXLE

•

TORQUE WRENCH SPECIAL TOOL
C-3281

RH418A

Fig.
61 Rotating
Pinion
Gear Ml

REMOVE SHIMS
BEARING PRELOAD
SHIM
PACK

PINION
LOCATING
SHIM
PACK

DIFFERENTIAL
BEARING
SHIM PACKS
RY660

Fig.
62
Shim
Locations
(18) Install a new yoke nut and tighten to 339-366
N-m (250-270 ft. lbs.) torque.

PINION
GEAR
DEPTH
MEASUREMENT
AND

ADJUSTMENT
WITH
TOOL
SET
C-758-D6
The alternate measurement and adjustment proce­
dure involves using Pinion Depth Measurement Gauge Set C-758-D6 (Fig. 65). (1) Install the pinion rear bearing cup (Fig. 66)
with Installer D-lll and Handle C-4171.
Ensure the cup is correctly seated. (2) Install the pinion front bearing cup with In­
staller C-4203 and Handle C-4171 (Fig. 67). Assemble C-758-D6 Tool Set as described (Fig.

68);
SPECIAL
TOOL

C-452
J9102-31

Fig.
63
Pinion
Yoke
Removal

SPECIAL
TOOL C4735
SP-5184 C-3719-A
DIFFERENTIAL
HOUSING

J9203-56

Fig.
64
Pinion
Seal
Installation
SPECIAL
TOOL
SET C-758-D6

J9203-67

Fig.
65
Pinion
Adjustment Tools

•
.
C-4171 J9203-65
Fig.
66
Pinion
Rear Bearing Cup
Installation
BEARING
CUP DRIVER

INSTALLATION
TOOL
C-4203
HANDLE

Fig.
67
Pinion
Front Bearing Cup
Installation
•
Position Spacer (SP-5814 for Model 60) over Shaft
(SP-526)

•
Position pinion rear bearing on shaft

•
Position tools (with bearing) in the housing

•
Install pinion front bearing

•
Install Sleeve
(SP-535-A),
Washer (SP-534) and
Nut
(SP-533).
(3) Prevent compression sleeve tool from turning
with Wrench C-3281. Tighten the nut to seat the pin­ ion bearings in the housing (Fig. 68). 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
FRONT SUSPENSION
AND
AXLE
2 - 69

Fig.
68 Seating
Pinion
Bearings
of the depth shim(s) is determined according to
the following information.
(4) 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 to 3
Nnn (15 to 25 in. lbs.) torque. Rotate the pinion gear several complete revolutions to align the bearing
rollers.
(5) Install Gauge Block SP-5260 at the end of SP-

526.
Install Cap Screw (SP-536) and tighten with
Wrench
SP-531.

(6) Position Crossbore Arbor (SP-5183) in the
dif­

ferential housing.
Center the arbor in cradles so equal space exists at
both ends. Position the bearing caps on the arbor
tool. Install the bolts. Tighten the cap bolts to 14 Nnn (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 69). 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.
69 Depth
Shim(s)
Selection

SPECIAL
TOOL