Dodge Ram Truck 1500-2500-3500. Manual — part 98
7. Install pinion into the housing (2) and place front
pinion bearing onto the pinion shaft. Draw the pin-
ion shaft into the front bearing with Installer 8982
(1).
8. Install new pinion seal with Installer 8882 (2) and
Handle C-4171 (1).
9. Apply a light coat of teflon sealant to the pinion
flange splines.
10. Hold pinion and lightly tap the pinion flange onto
the pinion shaft, until a few threads are showing.
11. Install pinion flange washer and new pinion nut.
12. Hold pinion flange with Flange Wrench 8979 and
tighten pinion nut until end play is taken up.
13. Rotate pinion several times to seat bearings.
14. Measure pinion (1) rotating torque with an inch
pound torque wrench (2). Tighten pinion nut in
small increments until pinion rotating torque is:
•
New Pinion Bearings: 1.7-2.8 N·m (15-25 in.
lbs.)
•
Original Pinion Bearings: 1.1-2.2 N·m (10-20
in. lbs.)
15. Rotate pinion several times then verify pinion
rotating torque again.
16. Position the ring gear on differential case and
start two new ring gear bolts.
17. Install the rest of the new ring gear bolts and
tighten them alternately to seat the ring gear.
18. Torque ring gear bolts to 140 N·m (103 ft. lbs.).
19. Install differential in housing.
20. Measure final rotating torque with an inch pound
torque wrench. The final pinion rotating torque
plus differential case bearing preload is:
•
New Bearings: 3.4-5.6 N·m (30-50 in. lbs.)
•
Original Bearings: 2.8-5.1 N·m (25-45 in. lbs.)
21. Install axle shafts.
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FRONT AXLE - 9 1/4 AA
DR/DH
22. Verify ring gear backlash and gear contact pattern.
23. Install the propeller shaft with the reference marks aligned.
24. Install differential cover with gasket and tighten to 40 N·m (30 ft. lbs.).
25. Fill differential with fluid and tighten fill plug to 32 N·m (24 ft. lbs.).
DR/DH
FRONT AXLE - 9 1/4 AA
3 - 225
REAR AXLE - 9 1/4
TABLE OF CONTENTS
page
page
REAR AXLE - 9 1/4
. . . . . . . . . . . . . . . . . . . 226
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
. . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . 238
. . . . . . . . . . . . . . . . . . . . . . . 239
SHAFT-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
. . . . . . . . . . . . . . . . . . . . . . . . 243
SEAL-AXLE SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
. . . . . . . . . . . . . . . . . . . . . . . . 244
BEARING-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . . . . . . . . . . 245
SEAL-PINION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
. . . . . . . . . . . . . . . . . . . . . . . . 247
COVER-DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
. . . . . . . . . . . . . . . . . . . . . . . . 248
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
. . . . . . . . . . . . . . . . . . . . . . . . 250
. . . . . . . . . . . . . . . . . . . . . . . . . . . 251
. . . . . . . . . . . . . . . . . . . . . . . . 253
DIFFERENTIAL-TRAC-LOK
. . . . . . . . . . . . . . . . . . . . . . . . . . 254
BEARING-DIFFERENTIAL CASE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
. . . . . . . . . . . . . . . . . . . . . . . . 256
GEAR-PINION/RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
. . . . . . . . . . . . . . . . . . . . . . . . 260
REAR AXLE - 9 1/4
DIAGNOSIS AND TESTING
REAR AXLE - 9 1/4
GEAR NOISE
Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, 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. They usually do not cause noise during
straight-ahead driving when the gears are unloaded. The side gears are loaded during vehicle turns. A worn pinion
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.
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REAR AXLE - 9 1/4
DR/DH
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.
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 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by:
•
Worn U-joint.
•
Worn side gear thrust washers.
•
Worn pinion shaft bore.
VIBRATION
Vibration at the rear of the vehicle is usually caused by a:
•
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 rearend vibration. Do not overlook engine accessories, brackets and drive belts.
NOTE: 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.
•
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. Listen for the noise, a
mechanics stethoscope is helpful in isolating the source of a noise.
DR/DH
REAR AXLE - 9 1/4
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