Dodge Sprinter. Manual — part 11
REAR AXLE
TABLE OF CONTENTS
page
page
REAR AXLE
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STANDARD PROCEDURE - DRAIN AND FILL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 16
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SHAFT-AXLE SINGLE REAR WHEEL
INSTALLATION-SINGLE REAR WHEEL
BEARING/SEAL-AXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . 26
SHAFT-AXLE DUAL REAR WHEELS
BEARING/SEAL-AXLE HUB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 29
DIFFERENTIAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 37
BEARINGS-DIFFERENTIAL CASE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . 38
SEAL-PINION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . 40
GEAR-PINION/RING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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REAR AXLE
DIAGNOSIS AND TESTING
NOTE: Axle seals, axle bearings, pinion seals and
differential cover are the only serviceble compo-
nents. If differential is damaged/noisy the axle must
be replaced.
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, 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 accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate 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 vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping 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 differen-
tial. 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.
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.
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REAR AXLE
VA
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
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 contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined 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 deter-
mined with the assistance of a helper. Raise the vehi-
cle 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.
STANDARD PROCEDURE - DRAIN AND FILL
NOTE: Drain oil when warm.
(1) Clean area around oil fill plug and drain plug.
(2) Remove oil drain plug (2) and drain oil (Fig. 1).
(3) Install oil drain plug and tighten to N·m 100
(74 ft. lbs.).
(4) Remove oil fill plug (1) and fill housing up to
bottom edge of oil fill hole (Fig. 1).
(5) Install oil fill plug and tighten to N·m 100 (74
ft. lbs.).
Fig. 1 FILL PLUG
1 - FILL PLUG
2 - DRAIN PLUG
VA
REAR AXLE
3 - 13
REMOVAL
Fig. 2 SINGLE REAR WHEEL AXLE
1 - REAR SPRING
12 - WEAR INDICATOR CONNECTOR
2 - U-BRACKET
13 - BRAKE HOSE
3 - PLATE
14 - WHEEL BOLT
4 - NUT
15 - BOLT
5 - BRAKE CABLE
16 - NUT
6 - REAR AXLE
17 - PROPELLER SHAFT
7 - ABL LEVER
18 - BOLT
8 - NUT
19 - ABS SENSOR
9 - SHOCK ABSORBER
20 - SENSOR BUSHING
10 - BOLT
21 - VENT LINE
11 - WEAR INDICATOR CABLE
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REAR AXLE
VA
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle
and secure axle to device.
(3) Remove wheels and tires.
(4) Unplug wear indicator cable (Fig. 2) and (Fig.
3).
(5) Detach cable connector for brake pad wear
indicator.
(6) Remove ABS sensor and clamp bushing from
mounting bore.
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
(7) Remove cable ties from the park brake cables.
Release connection cable of brake pad wear indicator
and ABS sensor cable up to the relay unit of the
parking brake.
(8) Remove brake cables.
(9) Remove hand brake cable at relay unit.
(10) Remove bracket for brake cables at rear axle
tube.
(11) Remove stabilizer bar from axle brackets.
(12) Remove shock absorber bolts from rear axle.
(13) Remove ALB lever from rear axle bracket.
(14) Pull vent line of rear axle out of frame.
(15) Remove propeller shaft.
(16) Remove brake calipers.
(17) Remove U-brackets and plates (Fig. 2) and
(Fig. 3).
(18) Remove axle from the vehicle.
Fig. 3 DUAL REAR WHEEL AXLE
1 - SPRING
12 - BRAKE HOSE
2 - SPRING SHACKLE
13 - LUG NUT
3 - PLATE
14 - NUT
4 - COLLAR NUT
15 - WASHER
5 - BRAKE CABLE
16 - BOLT
6 - REAR AXLE
17 - SHOCK ABSORBER
7 - ALB LEVER
18 - PROPELLER SHAFT
8 - NUT
19 - BOLT
9 - BOLT
20 - ABS SENSOR
10 - WEAR INDICATOR CABLE
21 - SENSOR BUSHING
11 - WEAR INDICATOR CONNECTOR
VA
REAR AXLE
3 - 15
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