Bearing nut DODGE TRUCK 1993 Service Repair Manual

0
- 22
LUBRICATION
AND
MAINTENANCE

DRIVETRAIN

INDEX

page

Axles
25
Clutch
and
Brake Pedal
Bushings
............ 22

Clutch Master Cylinder
22

Drive Shafts
26
page

Front Axle U-Joint
and
Pivot Bearings
......... 26

Transfer
Case
(4WD
Vehicles)
. . ........ 24

Transmissions
. 22

CLUTCH
AND
BRAKE PEDAL
If the clutch and brake pedal mechanism squeaks,
the pivot bushings should be lubricated (Fig. 1). Use
MOPAR®Multi-Purpose Lubricant, or an equivalent.

CLUTCH
MASTER CYLINDER
HYDRAULIC FLUID LEVEL The clutch master cylinder fluid level should be in­
spected at the same time as underhood maintenance
is conducted. The fluid level should be at indicating
line (Fig. 1). If the fluid level is low, locate and cor­
rect any possible leaks. Fill the reservoir with clean,
moisture-free brake fluid.
FLUID SPECIFICATION The only fluid recommended for use is
MOPAR®Brake Fluid, or an equivalent product. The
SLAVE

CYLINDER
CLUTCH
HOUSING
23
N«m
(200 IN.
LBS.)
product is identified as SAE J-1703 or DOT 3 flu­
id.Do not use any other type of
fluid.

CAUTION:
Never
use
reclaimed brake fluid
or
fluid
from
an
unsealed container.
Do not use
fluid that
has
been opened
and
allowed
to
stand
for an ex­

tended length
of
time.
TRANSMISSIONS

SPECIAL ADDITIVES Chrysler Motors does not recommend the addition
of any special additives to a transmission. Black
light detection dye can be used as an aid in detecting
fluid leaks.
RESERVOIR

STUD
VIEW
IN
DIRECTION
GtAKBQWZ

LUBRICATE
CLUTCH
PEDAL
23 N#m
(200 IN. LBS.)
5
N«m
(40 IN.
LBS

MASTER

CYLINDER
COTTER
PIN

NUT
23 N*m (200 IN.
LBS.) WAVE WASHER RETAINING RING

BRAKE
PEDAL VIEW
IN
DIRECTION FLAT WASHER
OF ARROW
Y
RR06F1

Fig.
1
Clutch
& Brake
Pedal
Mechanism

•

LUBRICATION
AND
MAINTENANCE
0 - 29
POWER STEERING SYSTEM

SERVICE SCHEDULE

FLUID
LEWEL

WARNING.
THE
POWER
STEERING
FLUID LEVEL
SHOULD
ALWAYS
BE
CHECKED
WITH THE EN­

GINE
OFF TO
PREVENT
PERSONAL
INJURY.

The power steering fluid should be checked when­
ever the engine is being serviced for other reasons. Clean the outside of the cap before removing. The
fluid should be at the proper level indicated on cap dipstick (Fig. 1).

Fig.
1
Power
Steering Reservoir & Cap—Typical
The reservoir fluid level can be determined with
the fluid either hot or cold. If the fluid level is below
the FULL HOT or FULL COLD marks on the dip­ stick, add power steering fluid. The dipstick is at­
tached to the reservoir cap (Fig. 1).
FLUID SPECIFICATION MOPAR03)Power Steering Fluid is highly recom­
mended.

FRONT
WHEEL BEARINGS
INSPECTION/LUBRICATION SCHEDULE

2WD
VEHICLES
It is recommended that 2WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least: • At each 39 000 km (24,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule • At each 36 000 km (22,500 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant.
4WD
VEHICLES

It is recommended that 4WD front wheel bearings
be inspected for proper lubrication whenever the
brake rotors are removed or at least:
• At each 24 000 km (15,000 miles) interval for ve­
hicles subject to the LIGHT DUTY CYCLE Mainte­ nance Schedule
• At each 19 000 km (12,000 miles) interval for ve­
hicles subject to the HEAVY DUTY CYCLE Mainte­ nance Schedule
For vehicles used for extensive off-road, 4WD
operation, the front wheel bearings should be in­ spected every 1 600 km (1,000 miles).
The bearings should be cleaned and re-packed
with a high temperature, multi-purpose EP lu­
bricant whenever the disc brake rotors are re­ surfaced.
INSPECTION If the lubricant:
• Is not sufficient
• Contaminated with foreign particles
• Appears dry or has been contaminated with water
to produce a milky appearance, the bearings should
be cleaned and re-packed with lubricant.

CAUTION:
Do not add
lubricant
to the
wheel
bear­
ings.
Re-pack completely. Mixing
of
different
types
of lubricants
in
wheel
bearings should
be
avoided.
This could possibly result
in
excessive thinning
and
leakage
of the
lubricant.

LUBRICATION (1) Discard the original seal.
(2) Clean the original lubricant from the bearings
and from the hub cavity (Figs. 2 and 3).
(3) Inspect the bearing rollers for indications of
pitting. Light bearing roller discoloration is consid­ ered normal. A wheel bearing must be replaced if any serious damage exists.
(4) Re-pack the bearings with a high temperature,
multi-purpose NLGI GC-LB lubricant. The use of a
bearing packer is recommended. A small amount of fresh lubricant also should be added to the hub cav­ ity.
BEARING INSTALLA TION/ADJUSTMENT (1) Install the hub/rotor (with inner bearing and
seal) on steering knuckle spindle.
(2) Install the outer bearing, the thrust washer
and the nut.
(3) Tighten wheel bearing nut to 27-34 N^m (240-
300 in. lbs.) torque while rotating hub/rotor. This
will seat the bearings.
(4) Loosen the nut 1/4 of-a-turn (90°), then tighten
it finger-tight.

0 - 30
LUBRICATION
AND
MAINTENANCE
— - •

Fig.
2 Front
Wheel
Bearing—2WD Vehicles
Fig.
3 Front
Wheel
&
Spindle
Bearings—4WD

Vehicles

(5) Position nut lock on the nut with one pair of
slots aligned with the cotter pin hole. Install the cot­
ter pin.
(6) Install the dust cap and wheel/tire. Tighten the
wheel lug nuts to 115 N*m (85 ft. lbs.) torque. Install
the wheel cover.

LUBRICANT SPECIFICATION
Use a high temperature, multi-purpose NLGI
GC-LB lubricant (MOPAR®Wheel Bearing Lubricant,
or an equivalent lubricant).
REAR
WHEEL BEARINGS
LUBRICATION
DANA
60
AND
70
AXLES
The rear wheel bearings for vehicles equipped with
a Dana 60 or 70 axle should be cleaned and re­
packed whenever the rear brakes are serviced. Refer
to Group 3—Rear Axles for the service procedure.

CHRYSLER
AXLES
, Vehicles equipped with 8 3/8-inch and 9
1/4-inch

axles have axle shaft bearings instead of wheel bear­

ings.
These bearings are lubricated by the axle hous­
ing sump.

LOWER
AND UPPER
SUSPENSION
ARM

BUSHINGS

INSPECTION
SCHEDULE
The lower and upper suspension arm bushings
should be inspected each time the underside of the
vehicle is serviced.

INSPECTION
The lower suspension arm bushings can be visually
inspected by raising the vehicle on a hoist and in­ specting from underneath. The upper suspension arm
bushings can be inspected after removing the front wheels. If failure exists, replace the bushing (refer to Group 2—Front Suspension for the proper proce­

dures).

The suspension arm bushings never should be
lubricated.

GUIDELINES
(1) Faulty bushings are detected by the bushing
being off-center in relation to the outer sleeve.
(2) Total failure is evident by excessive movement
within the bushing.

(3)
Small cracks in the outer, non-confined rubber
does not indicate failure of the rubber. '

POWER BRAKE SYSTEM
Vehicles are equipped with power disc brakes at
the front wheels and drum brakes at the rear wheels.

MASTER CYLINDER

FLUID
LEVEL INSPECTION
The brake fluid level should be inspected at the
same time as other underhood service is done (Fig.

4).
If necessary, add fluid to raise the level to the
bottom of the split rings. With disc-brakes, the fluid level can be expected to lower as the brake pads
wear. However, a low fluid level can also be caused
by a leak, and repair will then be necessary.

2
- 8
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) If a bearing and cup must be replaced, remove
the cup from the wheel hub/rotor bore (Fig. 1). Use a
brass drift or an appropriate removal tool to tap out
the cup.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool. (3) Apply lubricant to surface area of the wheel
hub/rotor bore. Install the inner wheel bearing in the
hub/rotor. Install a replacement bearing seal with an appropriate seal installation tool. (4) Inspect the bearing and seal contact surfaces on
the steering knuckle spindle for burrs and/or rough­ ness (Fig. 1).
(5) Remove all the rough contact surfaces from the
spindle. Apply a coating of multi-purpose NLGI,
grade 2, EP-type lubricant to the spindle surface.
CAUTION: Us© care to prevent the inner
wheel
bear­
ing
and bearing
seal
from contacting the steering

knuckle
spindle
threads during removal (Fig. 1).

Otherwise,
the threads, bearing, and
seal
could
be

damaged.

(6) Carefully slide the wheel hub/rotor onto the
spindle.
Install the outer wheel bearing, the washer and
nut.
(7) Tighten the nut to 41 to 54 Nnn (30 to 40 ft.
lbs.) torque while rotating the wheel hub/rotor. Stop
the hub/rotor and loosen the nut to completely re­
lease the bearing preload torque. Next, tighten the
nut finger-tight, install the nut lock. Install a re­
placement cotter pin.
(8) The wheel bearing adjustment (above) should
have 0.001 to 0.003 inch (0.254 to 0.0762 mm) end
play.
(9) Clean the dust cap. Apply a coating of multi­
purpose NLGI, grade 2, EP-type lubricant to internal surface. Install the cap. Do not fill the dust cap with lubricant. (10) Install the brake caliper, refer to Group 5,
Brakes. (11) Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.

LOWER SUSPENSION ARM STRUT

REMOVAL (1) Raise and support the vehicle.
(2) Use a small drift and a hammer to drive the
spring pin from the front of the strut. Remove the
spring pin, nut, retainer and bushing from the end of
the strut (Fig. 2).
(3) Remove the strut rear bolts and jounce bumper
from the bracket. Remove the strut from the vehicle (Fig. 2).
NUT

FRONT
RETAINER
STRUT
J9002-120
Fig. 2 Lower Suspension Arm Strut Removal/ Installation INSTALLATION
(1) Position the rear retainer and rear bushing on
the front end of the strut (Fig. 2).
(2) Carefully slide the strut into position. Install
the rear bolts. Tighten the bolts to 182 Nnn (135 ft. lbs.) torque.
(3) Install the front bushing, front retainer and
nut at the front end of the strut. Tighten the nut
with 70 Nnn (52 ft. lbs.) torque.
(4) Install the spring pin.

STABILIZER
BAR
REMOVAL
(1) Remove the link rod nut at each end of the sta­
bilizer bar (Fig. 3). Fig. 3 Stabilizer Bar

2
- 10
FRONT SUSPENSION
AND
AXLE

• INSTALLATION
(1) Position the spring and isolation pad on the
suspension arm. Install the spring compressor tool.
Compress the spring until the lower suspension arm
can be properly positioned in the steering knuckle.
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
the lower nut.
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
• 3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque Install replacement cotter pins.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle. (10) Test the vehicle brakes and the suspension for
proper operation.

LOWER SUSPENSION
ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mounting bolt from the cross-
member. (3) Remove the lower suspension arm from vehicle.
INSTALLATION (1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa­
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn (225 ft. lbs.) torque.

LOWER
BALL
STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far outboard as possible. The upper suspension arms
must not contact the rebound bumpers. (2) Install a dial indicator and clamp assembly to
the lower suspension arm. (3) Position indicator plunger against knuckle arm
and zero indicator. (4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint. REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov­
er/Installer C-4212 to force the ball stud out of the
lower suspension arm bore (Fig. 6).

Fig.
6
Lower
Bail
Stud
Removal

INSTALLATION (1) Force the replacement ball stud into the lower
suspension arm bore with assembled Remover/In­
staller C-4212 (Fig. 7).
Fig.
7
Lower
Ball
Stud
Installation

•

Fig.
11 Upper Suspension Arm Bushing installation

STEERING KNUCKLE
REMOVAL
(1) Block the brake pedal in the up position. Raise
the vehicle and remove the wheel cover and wheel/
tire.
Remove the brake caliper, refer to Group 5,
Brakes. (2) Remove the brake rotor from the spindle. Refer
to Wheel Hub and Bearings service procedures
within this Group.
(3) Remove the brake splash shield. Remove and
discard the dust seal.
(4) Remove the cotter pin and the nut from the tie-
rod end ball stud.

(5)
Install Puller Tool C-3894A (Fig. 12) and apply
sufficient force with the tool to loosen the tie-rod end
ball stud from the steering knuckle arm bore.
Fig.
12 Tie-Rod End
Ball
Stud
Removal
FRONT SUSPENSION
AND
AXLE
2 - 13

Fig.
13 Steering
Knuckle

(16) Remove the brake adapter and steering
knuckle bolts from the steering knuckle. Separate
the components.
INSTALLATION (1) Install the brake adaptor on the steering
knuckle. Tighten the bolts to 136 Nnn (100 ft-lbs)
torque.
(2) Align the steering knuckle arm bolt holes with
the steering knuckle bolt holes. Install the bolts and
tighten to 291 Nnn (215 ft-lbs) torque. (6) Remove the shock absorber from the vehicle,
refer to the removal procedures. (7) Install Spring Compressor Tool DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(8) Remove the cotter pins and the lower and up­
per ball stud nuts at the steering knuckle.
(9) Install Ball Stud Loosening Tool C-3564-A on
the lower ball stud (Fig. 4). Turn the threaded por­
tion of the tool and lock the tool securely against the lower stud (Fig. 5). Expand the tool enough to place
force on the lower ball stud. Strike the steering
knuckle sharply with a hammer to loosen the stud.
Do not attempt to force the stud out of the steer­
ing knuckle with the loosening tool.
(10) Remove the loosening tool and remove the
lower ball stud from the steering knuckle bore with an appropriate tool.
(11) Reverse the position of Ball Stud Loosening
Tool C-3564-A, and remove the upper ball stud.
(12) Remove the loosening tool.
(13) Remove the upper ball stud from the steering
knuckle bore with an appropriate tool. (14) Slowly loosen the coil spring compressor tool
(Fig. 5) until all tension is relieved from the spring.
(15) Separate the steering knuckle and the steer­
ing knuckle arm from the ball studs (Fig. 13).

2
- 20
FRONT SUSPENSION
AND
AXLE

•
INSTALLATION

(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 5) use In­
staller W-147-E and Handle C-4171.

Fig.
5
Pinion
Seal
Installation

(2) Align the installation reference marks and po­
sition the yoke on the pinion gear.
(3) Install the pinion yoke, washer, and nut on
shaft. Tighten the nut to 271-298 N»m (200-220 ft.
lbs.) torque (Fig. 6).
DIFFERENTIAL
Fig.
6 Tightening
Pinion
Shaft Nut (4) Align the installation reference marks and at­
tach the drive shaft to the yoke.
(5) Add API grade GL 5 hypoid gear lubricant to
the differential housing, if necessary.
(6) Lower the vehicle.

HUB, SPINDLE
AND
AXLE SHAFT
REMOVAL/DISASSEMBLY
(1) Raise and support the front of vehicle.
(2) Remove the wheel/tire.
(3) Remove the brake caliper and adapter, refer to
Group 5, Brakes. Support the caliper to the frame
structure with wire.
(4) Remove the dust cap and drive hub snap ring
(Fig. 7).

Fig.
7 Drive Hub
Snap Ring

(5) Remove the drive hub and spacer (Fig. 8).
(6) Remove the wheel bearing outer lock nut with
Wrench C-4170-A (Fig. 9). (7) Remove the lock washer and inner lock nut
(Fig. 10).
(8) Remove the hub and rotor assembly from the
spindle.
(9) Remove the nuts that attach the spindle to the
steering knuckle. Remove the spindle from the
knuckle, use a soft faced mallet if necessary to tap
loose (Fig. 11).
(10) Pull the axle shaft (with spacer, seal and
slinger) from the steering knuckle (Fig. 12). (11) Clamp the spindle in a soft-jawed vise. Do not
clamp at the bearing contact surfaces. Remove the
bearing seal. (12) Use Puller D-131 to remove needle bearings
from the spindle (Fig. 13).

•

Fig.
8
Spacer
Removal/Installation

Fig.
9
Wheel
Bearing
Lock
Nut
Removal
ASSEMBL
Y/INSTALLA
TION

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

ings.
Install a new needle bearing in the spindle with
Installer D-122 and Handle C-4171 (Fig. 14).
(2) Lubricate and install a new spindle seal with
Installer D-155 and Handle C-4171 (Fig. 15).
(3) Install the seal with lip facing the axle shaft
splines (Fig. 16). Lubricate the seal (Fig. 17) with
Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant).
FRONT
SUSPENSION
AND
AXLE
2 - 21

LOCK
WASHER INNER LOCK
NUT

Fig.
10
Lock
Washer
Removal/Installation
Fig.
11
Spindle
Removal
(4) Right side only: carefully install the axle shaft
through the knuckle into the axle housing. Ensure
the axle shaft splines are engaged with the differen­
tial side gears. Avoid damaging the differential
seals.

(5) Left side only: remove the shift motor housing
from axle. Position the shift collar on the intermedi­ ate axle shaft. Install the axle shaft, ensure the axle
shaft splines are engaged with the shift collar. In­ stall the shift motor (ensure the fork is engaged with
the shift collar) and tighten the bolts to 14 Nnn (10
ft. lbs.) torque.
(6) Install the spacer on the axle shaft end.
(7) Install the brake splash shield and spindle on
the steering knuckle. Install new nuts and tighten to 34-41 Nnn (25-35 ft. lbs.) torque (Fig. 18).

2
- 22
FRONT SUSPENSION
AND
AXLE
——
J9202-79
Fig. 12 Axle Shaft Removal
Fig. 13 Spindle Needle Bearing Removal (8) Install the hub and rotor assembly onto the
spindle. Add Wheel Bearing Grease lubricant (NLGI Grade 2, EP or an equivalent lubricant) to the bear­

ings.

(9) Install the wheel bearing inner lock nut on the
spindle with Wrench C-4170 (Fig. 19). Tighten the
lock nut to 68 N*m (50 ft. lbs.) torque 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 (Fig. 8). Install and tighten the outer nut lock with Wrench C-4170 (Fig. 19 ) to 68
N«m (50 ft. lbs.) torque. The end play after the final •
Fig. 14 Spindle Needle Bearing Installation Fig. 15 Seal Installation bearing adjustment should be within 0.001 inch to
0.010 inch (0.03 to 0.25 mm).
(13) Install the spacer, driving hub and ring (Fig.

7,
8). Ensure the ring is seated.
(14) Apply MOPAR® Silicone Rubber Sealant to
the edge of the dust cap and install cap onto hub. (15) Install the brake caliper and adapter, refer to
Group 5, Brakes. (16) Install the wheel and tire, refer to Wheel and
Tire—Installation within this section. Lower the ve­ hicle. STEERING
AXLE
SHAFT

•

FRONT
SUSPENSION
AND
AXLE
2 - 23

RN328

Fig.
17 Lubricating Axle Shaft
Seal

Fig.
18
Spindle
Installation

AXLE SHAFT AND
U-JOINT
SERVICE DISASSEMBLY

(1) Remove the snap rings from the yokes.
Fig.
19
Wheel
Bearing Lock Nut
Installation

(2)
Position the U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.

Fig.
20 Bearing Cap
Removal

(3)
Use a mallet to drive the vertical yoke down­
ward to remove the upper needle bearing and cap out (Fig. 20).

(4)
Reverse the position of the yoke and remove op­
posite needle bearing and cap (Fig. 20).

(5)
Remove the yoke from the spider.
(6)
Position the open ends of the spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove remaining bearings and caps.
(7) Remove the spider from the yoke.
(8) Clean and inspect all the components. Clean
any rust from the axle shaft splines. Retain each
bearing and cap separate. If any component is exces­ sively worn or damaged, replace the U-joint.