Dodge Dakota (ND). Manual — part 32
8. Install Pilot Stud C-3288-B (2) in cover bolt hole
below ring gear.
9. Attach Dial Indicator C-3339 (3) to post and posi-
tion dial indicator plunger on a flat surface on a
ring gear bolt head.
10. Push and hold differential to the pinion gear side
(1) of the housing and zero dial indicator (3).
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FRONT AXLE - C205F
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11. Push and hold differential case to the ring gear
side (3) and record dial indicator (1) reading.
12. Add the dial indicator reading to the starting point
shim thicknesses to determine the total shim
thickness necessary to achieve zero differential
end play.
13. Add 0.2 mm (0.008 in) to the zero end play total.
This new total represents the shims needed to
preload the new differential case bearings.
14. Rotate dial indicator out of the way on pilot stud.
15. Remove differential case, dummy bearings and
dummy shims from the housing.
16. Install the pinion gear in the housing. Install the
companion flange and establish the correct pinion
rotating torque.
17. Install differential case and Dummy Bearings in
the housing with a single dummy shim on the ring
gear side of the axle and tighten retaining cap
bolts.
18. Position the dial indicator plunger on a flat surface
between the ring gear bolt heads.
19. Push and hold differential case toward pinion.
20. Zero dial indicator face to pointer.
21. Push and hold differential case to ring gear side of the housing.
22. Record dial indicator reading.
23. Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pin-
ion gears. Add the resulting measurement to the thickness of the single dummy shim. This is the thickness of
shim required to achieve proper backlash.
24. Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thick-
ness required on the pinion side of the housing.
25. Rotate dial indicator out of the way on pilot stud.
26. Remove differential case, dummy bearings and dummy shim from the housing.
27. Install new side bearing cones and cups on differential case.
28. Install Spreader W-129-B and Adapter Plates 8142-A on the housing and spread open enough to receive dif-
ferential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or dam-
aged.
29. Place the side bearing shims in the differential housing against the housing shoulder.
30. Install the differential case in the housing.
31. Rotate the differential case several times to seat the side bearings.
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FRONT AXLE - C205F
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GEAR BACKLASH
1. Position the dial indicator (1) plunger against a ring
gear tooth (2).
2. Push and hold ring gear upward while not allowing
the pinion gear to rotate.
3. Zero dial indicator face to pointer.
4. Push and hold ring gear downward while not allow-
ing the pinion gear to rotate. Dial indicator reading
should be between 0.12 mm (0.005 in.) and 0.20
mm (0.008 in.). If backlash is not within specifica-
tions transfer the necessary amount of shim thick-
ness from one side of the differential housing to the
other.
5. Verify differential case and ring gear runout by
measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should
not vary more than 0.05 mm (0.002 in.). If readings
vary more than specified, the ring gear or the dif-
ferential case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
1. Wipe clean each tooth of the ring gear.
2. Apply gear marking compound to all of the ring
gear teeth.
3. Verify bearing cap bolts are torque specification.
4. Apply the brakes lightly to create at 14 N·m (10 ft.
lbs.) pinion rotating torque.
5. Rotate the pinion/pinion yoke 4 full revolutions in
each directions.
6. Read gear tooth contact pattern.
Gear contact pattern correct. Backlash and pinion
depth is correct.
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Ring gear too far away from pinion gear coast side toe
(1) drive side heel (2). Decrease backlash by moving
the ring closer to the pinion gear.
Ring gear too close to pinion gear drive side toe (1)
coast side heel (2). Increase backlash, by moving the
ring away from the pinion gear.
Ring gear too far away from pinion gear drive side
heel (1) coast side heel (2). Decrease backlash, by
moving the ring closer to the pinion gear.
Ring gear too close to pinion gear drive side toe (1)
coast side toe (2). Increase backlash, by moving the
ring away from the pinion gear.
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FRONT AXLE - C205F
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