Dodge Ram Truck 1500-2500-3500. Manual — part 109

Condition

Possible Causes

Correction

Axle Overheating

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct
fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.

Gear Teeth Broke

1. Overloading.

1. Replace gears. Examine other
gears and bearings for possible
damage.

2. Erratic clutch operation.

2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine
remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

Axle Noise

1. Insufficient lubricant.

1. Fill differential with the correct
fluid type and quantity.

2. Improper ring gear and pinion
adjustment.

2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.

3. Unmatched ring gear and pinion.

3. Replace gears with a matched
ring gear and pinion.

4. Worn teeth on ring gear and/or
pinion.

4. Replace ring gear and pinion.

5. Loose pinion bearings.

5. Adjust pinion bearing pre-load.

6. Loose differential bearings.

6. Adjust differential bearing
pre-load.

7. Mis-aligned or sprung ring gear.

7. Measure ring gear run-out.
Replace components as necessary.

8. Loose differential bearing cap
bolts.

8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.

9. Housing not machined properly.

9. Replace housing.

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REAR AXLE - 10 1/2 AA

DR/DH

REMOVAL

1. With vehicle in neutral, position vehicle on hoist.

2. Position a lift under axle and secure lift to the axle.

3. Remove all brake components.

4. Remove axle vent hose.

5. Mark propeller shaft and companion flange for

installation alignment reference.

6. Remove propeller shaft.

7. Remove shock absorbers (3) from axle (2).

8. Remove U-bolts (5) from axle.

9. Remove axle from the vehicle.

DR/DH

REAR AXLE - 10 1/2 AA

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INSTALLATION

1. Raise axle with lift and align to the leaf spring cen-

tering bolts.

2. Install axle U-bolts (5) and tighten to 149 N·m (110

ft. lbs.).

3. Install shock absorbers to axle and tighten to spec-

ification.

4. Install all brake components.

5. Install axle vent hose.

6. Install propeller shaft with reference marks aligned

and tighten to specification.

7. Fill differential to specifications.

ADJUSTMENTS

PINION DEPTH MEASUREMENT

Ring and pinion gears are supplied as matched sets.
Compensation for pinion depth variance is achieved
with a select shim. The shim is located between the
rear pinion bearing and the pinion gear head.

Measurements are taken with pinion bearing cups and
pinion bearings installed in the housing. Take mea-
surements with Pinion Gauge Set and Dial Indicator
C-3339.

1. Assemble Pinion Height Block 6739 (3), Pinion

Block 8899 (6) and rear pinion bearing onto Screw
6741 (5).

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REAR AXLE - 10 1/2 AA

DR/DH

2. Insert pinion block (1), pinion height block (2), rear

bearing and screw into the housing through pinion
bearing cups.

3. Install front pinion bearing and Cone-nut 6740 onto

the screw. Tighten cone-nut until Torque To Rotate
the screw is 1.7-2.26 N·m (15-20 in. lbs.).

4. Place Arbor Disc 6732 (1) on Arbor D-115-3 (3) in

position in the housing side bearing cradles.

5. Install differential bearing caps on arbor discs (1)

and snug the bearing cap bolts. Then cross tighten
cap bolts to 165 N·m (122 ft. lbs.).

NOTE: Arbor should rotate freely in the arbor
discs.

6. Assemble Dial Indicator C-3339 into Scooter Block

D-115-2 and secure set screw.

7. Position scooter block (2) with dial indicator (3)

flush on the pinion height block. Hold scooter block
and zero the dial indicator.

8. Slowly slide the scooter block (2) across the pinion

height block over to the arbor (1). Move the scooter
block till dial indicator crests the arbor, then record
the highest reading.

9. Select a shim equal to the dial indicator reading.

10. Install the select shim between the rear pinion

bearing and the pinion gear head.

DR/DH

REAR AXLE - 10 1/2 AA

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