Dodge ram truck 3500 1996 Service Manual page 91

B R
DIFFERENTIAL AND DRIVELINE 3 - 25
R E M O V A L A N D I N S T A L L A T I O N ( C o n t i n u e d )
ASSEMBLY
AMD
INSTALL
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset
should be toward the differential.
(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover. Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and
attaching bolts. Tighten the bolts to 11 N-m (96 in.
lbs.) torque.
(6) Add 148 ml (5 ounces) of API grade GL 5
hypoid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(7) Install indicator switch, electrical connector
and vacuum harness.
DRIVE AXLE ASSEMBLY REPLACEMENT
REMOVAL
(1) Raise vehicle and position support stands
under the frame rails behind the lower suspension
arm brackets.
(2) Remove the front wheels assemblies.
(3) Remove the brake components and ABS brake
sensor (if equipped). Refer to Group 5, Brakes.
(4) On 4WD vehicles, disconnect the axle vent
hose. Disconnect vacuum hose and electrical connec­
tor at disconnect housing.
(5) On 4WD vehicles, mark the drive shaft yoke,
axle pinion yoke and transfer case flange for align­
ment reference. Disconnect the drive shaft from the
axle and transfer case.
(6) Disconnect the stabilizer bar link at the axle
bracket.
(7) Disconnect the shock absorbers from axle
bracket.
(8) Disconnect the track bar from the axle bracket.
(9) Disconnect the tie rod and drag link from the
steering knuckle.
(10) Support the axle with a hydraulic jack under
the differential.
(11) Disconnect the upper and lower suspension
arms from the axle bracket. Mark cams for instal­
lation reference.
(12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle.
(13) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are tightened. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush­
ing wear may occur. Rubber bushings must never
be lubricated.
(1) Install the springs, retainer clip and bolts.
(2) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(3) Raise the axle with a floor jack and align it
with the spring pads.
(4) Position the upper and lower suspension arm
at the axle bracket. Install bolts, nuts and align cams
to reference marks. Do not tighten at this time.
(5) Connect the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
It is important that the springs support the
weight of the vehicle when the track bar is con­
nected. If the springs are not at normal ride
height, the vehicle ride comfort could be
affected.
(6) Install the shock absorber and tighten bolts to
121 N-m (89 ft. lbs.) torque.
(7) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 37 N-m (27 ft. lbs.)
torque.
(8) Install the drag link and tie rod to the steering
knuckles and tighten the nuts to 88 N-m (65 ft. lbs.)
torque.
(9) Install the brake components and ABS brake
sensor (if equipped). Refer to Group 5, Brakes.
(10) On 4WD vehicles, connect the vent hose to the
tube fitting. Connect vacuum hose and electrical con­
nector to disconnect housing.
(11) On 4WD vehicles, align the reference marks
and connect the drive shaft to the axle yoke and
transfer case flange. Tighten the U-joint clamp bolts
to 19 N-m (14 ft. lbs.) torque. Tighten flange bolts to
88 N-m (65 ft. lbs.) torque.
(12) Check differential lubricant and add i f neces­
sary.
(13) Install the wheel and tire assemblies.
(14) Remove the supports and lower the vehicle.
(15) Tighten the upper suspension arm nuts at
axle to 121 N-m (89 ft. lbs.) torque. Tighten the
upper suspension arm nuts at frame to 84 N-m (62 ft.
lbs.) torque.
(16) Tighten the lower suspension arm nuts at
axle to 84 N-m (62 ft. lbs.) torque. Tighten the lower
suspension arm nuts at frame to 119 N-m (88 ft. lbs.)
torque.
(17) Tighten the track bar bolt at the axle bracket
to 176 N-m (130 ft. lbs.) torque.
(18) Check the front wheel alignment.