Dodge RAM TRUCK 1500 1995 Service Manual page 142

3 -12 REAR SUSPENSION M i l AXLE — —
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When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install the axle shafts and C-clip locks and pin­
ion mate shaft. If necessary, refer to the installation
located within this group.
(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 29).
FIG, 29 Side Gear Clearance Measurement
(3) If side gear clearances is no more than 0.005
inch. Determine if the shaft is contacting the pinion
gear mate shaft. Do not remove the feeler
gauges, Inspect the axle shaft w i t h the feeler
gauge i n s e r t e d b e h i n d the side gear. If the end of
the axle shaft is not contacting the pinion gear mate-
shaft, the side gear clearance is acceptable.
(4) If clearance is more than 0.005 inch (axle shaft
not contacting mate shaft), record the side gear clear­
ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick­
ness to the recorded side gear clearance. The sum of
gear clearance and washer thickness will determine
required thickness of replacement thrust washer
(Fig. 30).
In some cases, the end of the axle shaft will move
and contact the mate shaft when the feeler gauge is
inserted. The C-clip lock is preventing the side gear
from sliding on the axle shaft.
(5) If there is no side gear clearance, remove the
C-clip lock from the axle shaft. Use a micrometer to
SIDE GEAR CLEARANCE 0.007
THRUST WASHER THICKNESS + 0.033
TOTAL 0.040
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0 . 0 4 0
REPLACEMENT WASHER THICKNESS
" 0 . 0 3 7
NEW SIDE GEAR CLEARANCE 0 . 0 ) 3
J9203-31
Fig. 30 Side Gear Calculations
measure the thrust washer thickness. Record the
thickness and re-install the thrust washer. Assemble
the differential case without the C-clip lock installed
and re-measure the side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or greater,
both side gears must be replaced (matched set) and
the clearance measurements repeated.
(8) If clearance (above) continues to be ,0.012 inch
(0.305 mm) or greater, the case must be replaced.
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ANALYSIS
The ring gear teeth contact patterns will show if
the pinion gear depth shim(s) have the correct thick­
ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main­
tained within the specified limits until the correct
teeth contact patterns are obtained.
© Excessive backlash is corrected by moving the ring
gear teeth closer to the pinion gear teeth
® Insufficient backlash is corrected by moving the
ring gear away from the pinion gear
(1) Apply yellow ferrous (iron) oxide compound to
both drive and coast sides of ring gear teeth.
(2) Rotate the ring gear one complete revolution in
both directions.
(3) Note patterns in compound. Refer to (Fig. 31)
for interpretation of contact patterns and adjust ac­
cordingly.
(4) Install the axle shafts. Refer to Axle Shaft In­
stallation within this group.
(5) Install the housing cover. Refill the differential
with lubricant.
(6) Install the RWAL/ABS brake speed sensor and
cover onto the axle housing. Tighten the sensor to 13
N-m (10 ft. lbs.) torque.