Dodge Ram Truck 1500-2500-3500. Manual — part 99

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.

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.

Differential Gears Scored

1. Insufficient lubrication.

1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

3. Excessive spinning of one
wheel/tire.

3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.

Loss Of Lubricant

1. Lubricant level too high.

1. Drain lubricant to the correct
level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal
cover.

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REAR AXLE - 9 1/4

DR/DH

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.

DR/DH

REAR AXLE - 9 1/4

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REMOVAL

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

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

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.

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REAR AXLE - 9 1/4

DR/DH

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 comonents.

5. Install axle vent hose.

6. Install propeller shaft with reference marks aligned

and tighten to specification.

7. Fill differential to specifications.

ADJUSTMENTS

Ring gear and pinion are supplied as matched sets.
Identifying numbers for the ring gear and pinion are
painted onto the pinion gear shaft and the side of the
ring gear. A plus (+) number, minus (–) number or zero
(0) along with the gear set sequence number (2) (01
to 99) is on each gear. This first number is the amount
(in thousandths of an inch) the depth varies (1) from
the standard depth setting of a pinion marked with a
(0). The next two numbers are the sequence number
of the gear set. The standard depth provides the best
teeth contact pattern.

DR/DH

REAR AXLE - 9 1/4

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