Dodge Ram Truck 1500-2500-3500. Manual — part 77
INSTALLATION
1. Clean all C/V joint components and shaft.
2. Slide new boot (1) down the half shaft.
3. Install tripod (2) and tripod snap ring on the half
shaft.
4. Pack grease supplied with the joint/boot into the
housing and boot.
5. Coat tripod with supplied grease.
6. Install new bushing (1) onto the housing (2).
7. Insert the tripod and shaft in the housing.
8. Position the boot (2) on the housing (5) and shaft
(4) in it’s original position.
NOTE: Verify boot is not twisted and remove any
excess air.
9. Measure the distance from the end of the housing
to the end of the boot on the shaft. This measure-
ment should be 260 mm (10.25 in.).
NOTE: If measurement is not correct, allow more
or less air into the boot.
10. Secure both boot clamps (1) (3) with Clamp
Installer C-4975A. Place tool on clamp bridge and
tighten tool until the jaws of the tool are closed.
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HALF SHAFT
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FRONT AXLE - C205F
TABLE OF CONTENTS
page
page
FRONT AXLE - C205F
. . . . . . . . . . . . . . . . . 141
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
. . . . . . . . . . . . . . . . . . . . . . . . 147
. . . . . . . . . . . . . . . . . . . . . . . 148
. . . . . . . . . . . . . . . . . . . . . . 158
. . . . . . . . . . . . . . . . . . . . . . . 159
SHAFT-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
. . . . . . . . . . . . . . . . . . . . . . . . 163
SEAL-AXLE SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
. . . . . . . . . . . . . . . . . . . . . . . . 164
BEARING-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
. . . . . . . . . . . . . . . . . . . . . . . . 165
SEAL-PINION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
. . . . . . . . . . . . . . . . . . . . . . . . 167
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
. . . . . . . . . . . . . . . . . . . . . . . . 170
. . . . . . . . . . . . . . . . . . . . . . . . . . . 170
. . . . . . . . . . . . . . . . . . . . . . . . 171
BEARINGS-DIFFERENTIAL CASE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
. . . . . . . . . . . . . . . . . . . . . . . . 172
GEAR-PINION/RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
. . . . . . . . . . . . . . . . . . . . . . . . 176
FRONT AXLE - C205F
DIAGNOSIS AND TESTING
FRONT AXLE - C205F
GEAR NOISE
Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears or
the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving
condition. These conditions are acceleration, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle
to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the
noise stops or changes greatly check for:
•
Insufficient lubricant.
•
Incorrect ring gear backlash.
•
Gear damage.
Differential side gears and pinions can be checked by turning the vehicle. The side gears are loaded during turns.
They usually do not cause noise during straight-ahead driving when the gears are unloaded. A worn pinion mate
shaft can also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be
either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will
be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing noise
occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front
pinion bearing is the source.
Differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing noise.
The pitch of differential bearing noise is also constant and varies only with vehicle speed.
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FRONT AXLE - C205F
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Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the
bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the
bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at
speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
•
Worn U-joints/CV joint.
•
Worn side-gear thrust washers.
•
Worn pinion shaft bore.
VIBRATION
Vibration at the rear of the vehicle is usually caused by:
•
Damaged drive shaft.
•
Missing drive shaft balance weight(s).
•
Worn or out of balance wheels.
•
Loose wheel lug nuts.
•
Worn U-joint(s).
•
Loose/broken springs.
•
Damaged axle shaft bearing(s).
•
Loose pinion gear nut.
•
Excessive pinion yoke run out.
•
Bent axle shaft(s).
Check for loose or damaged front end components or engine/transmission mounts. These components can contrib-
ute to what appears to be a rear end vibration. Do not overlook engine accessories, brackets and drive belts.
All driveline components should be examined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged) can be caused by:
•
High engine idle speed.
•
Transmission shift operation.
•
Loose engine/transmission/transfer case mounts.
•
Worn U-joints/CV joint.
•
Loose spring mounts.
•
Loose pinion gear nut and yoke.
•
Excessive ring gear backlash.
•
Excessive side gear to case clearance.
The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a
hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear and listen for the noise. A
mechanics stethoscope is helpful in isolating the source of a noise.
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FRONT AXLE - C205F
DR/DH
DIAGNOSTIC CHART
Condition
Possible Causes
Correction
Wheel Noise
1. Wheel loose.
1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing.
2. Replace bearing.
Axle Shaft Noise
1. Misaligned axle tube.
1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft.
2. Inspect and correct as necessary.
3. End-play in pinion bearings.
3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut.
6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke
1. Misaligned axle tube.
1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded.
2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation.
3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch.
4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked
1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash.
2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded.
3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation.
4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
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FRONT AXLE - C205F
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