Dodge ram truck 3500 1996 Service Manual page 86

3 - 20 DIFFERENTIAL AND DRIVELINE _ _ _ _ _
D I A G N O S I S A N D T E S T I N G (Continued)
CONTINUED
B R
C O N D I T I O N P O S S I B L E CAUSES C O R R E C T I O N
LOSS OF LUBRICANT 2. Worn axle shaft seals.
3. Cracked differential housing.
4. Worn drive pinion gear shaft
seal.
5. Scored and worn yoke.
6. Axle cover not properly sealed.
2. Replace worn seals.
3. Repair or replace housing as necessary.
4. Replace worn drive pinion gear shaft seal.
5. Replace worn or scored yoke and seal.
6. Remove cover and clean flange and reseal.
AXLE OVERHEATING 1. Lubricant level too low.
2. Incorrect grade of lubricant.
3. Bearings adjusted too tight.
4. Excessive gear wear.
5. Insufficient ring gear backlash.
1. Refill differential housing.
2. Drain, flush and refill with correct amount of the correct
lubricant.
3. Readjust bearings.
4. Inspect gears for excessive wear or scoring. Replace as
necessary.
5. Readjust ring gear backlash and inspect gears for possible
scoring. j
GEAR TEETH BROKE
(RING GEAR A N D PINION)
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavements.
4. Improper adjustments.
1. Replace gears. Examine other gears and bearings for possible
damage.
2. Replace gears and examine the remaining parts for possible ;.
damage. Avoid erratic clutch operation. j
3. Replace gears. Examine the remaining parts for possible
damage. Replace parts as required.
4. Replace gears. Examine other parts for possible damage.
Ensure ring gear backlash is correct.
AXLE NOISE
1. Insufficient lubricant.
2. Improper ring gear and drive
pinion gear adjustment.
3. Unmatched ring gear and drive
pinion gear.
4. Worn teeth on ring gear or
drive pinion gear.
5. Loose drive pinion gear shaft
bearings.
6. Loose differential bearings.
7. Misaligned or sprung ring gear.
8. Loose differential bearing cap
bolts
1. Refill axle with correct amount of the proper lubricant.
Also inspect for leaks and correct as necessary.
2. Check ring gear and pinion gear teeth contact pattern.
3. Remove unmatched ring gear and drive pinion gear.
Replace with matched gear and drive pinion gear set.
4. Check teeth on ring gear and drive pinion gear for correct
contact. If necessary, replace with new matched set.
5. Adjust drive pinion gearshaft bearing preload torque.
6. Adjust differential bearing preload torque.
7. Measure ring gear runout.
8. Tighten with specified torque
J9503-4