Dodge Ram Truck 1500-2500-3500. Manual — part 119
9. Apply a light coat of teflon sealant to the pinion
flange splines.
10. Hold the pinion and lightly tap the pinion flange
onto the pinion, until a few threads are showing.
11. Install pinion flange washer and new pinion nut.
12. Hold pinion flange (2) with Flange Wrench 8979
(1) and tighten pinion nut until pinion 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 (2) on differential case (4)
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.
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REAR AXLE - 10 1/2 AA
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18. Torque ring gear bolts to 237 N·m (175 ft. lbs.).
19. If exciter ring was removed, position differential
assembly on differential Plug 8888 and place
exciter ring on the differential case.
20. Install exciter ring (1) on the differential case
evenly with a hammer and brass punch (2). Drive
the ring down until it is seated against the ring
gear (3).
CAUTION: Do not damage exciter ring teeth during
installation.
21. Install differential into the housing.
22. Verify ring gear backlash and gear contact pat-
tern.
23. 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.)
24. Install axle shafts.
25. Install the propeller shaft with the reference marks aligned.
26. Install differential cover with gasket and tighten bolts to 40 N·m (30 ft. lbs.).
27. Fill differential with fluid and tighten fill plug to 32 N·m (24 ft. lbs.).
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REAR AXLE - 11 1/2 AA
TABLE OF CONTENTS
page
page
REAR AXLE - 11 1/2 AA
. . . . . . . . . . . . . . . . . 310
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
. . . . . . . . . . . . . . . . . . . . . . . . 315
. . . . . . . . . . . . . . . . . . . . . . . 315
. . . . . . . . . . . . . . . . . . . . . . 320
. . . . . . . . . . . . . . . . . . . . . . . 321
SHAFT-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
. . . . . . . . . . . . . . . . . . . . . . . . 325
BEARING-AXLE HUB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
. . . . . . . . . . . . . . . . . . . . . . . . 327
SEAL-PINION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
. . . . . . . . . . . . . . . . . . . . . . . . 329
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
. . . . . . . . . . . . . . . . . . . . . . . . 331
. . . . . . . . . . . . . . . . . . . . . . . . . . . 333
. . . . . . . . . . . . . . . . . . . . . . . . 335
DIFFERENTIAL-TRAC-RITE
. . . . . . . . . . . . . . . . . . . . . . . . 336
. . . . . . . . . . . . . . . . . . . . . . . . . . 337
. . . . . . . . . . . . . . . . . . . . . . . . . . . 337
BEARING-DIFFERENTIAL CASE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
. . . . . . . . . . . . . . . . . . . . . . . . 338
GEAR-PINION/RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
. . . . . . . . . . . . . . . . . . . . . . . . 341
REAR AXLE - 11 1/2 AA
DIAGNOSIS AND TESTING
REAR AXLE-11 1/2 AA
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. 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 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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REAR AXLE - 11 1/2 AA
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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 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by:
•
Worn U-joint(s).
•
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.
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 and listen for the noise. A
mechanics stethoscope is helpful in isolating the source of a noise.
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