Removal; Installation; Adjustments - Dodge dakota 2002 Service Manual

DR
FRONT AXLE - C205F (Continued)
Condition
Gear Teeth Broke
Axle Noise

REMOVAL

(1) Place transmission in netural.
(2) Raise and support the vehicle.
(3) Remove tire and wheel assemblies.
(4) Remove axle half shafts.
(5) Remove exhaust crossover.
(6) Mark front propeller shaft and remove shaft.
(7) Remove suspension crossmember mounting
bolts (Fig. 1) and remove crossmember.
(8) Support axle with hydraulic jack.
(9) Remove axle housing pinion mounting bolts
(Fig. 2).
(10) Remove axle shaft tube mounting bolts (Fig.
3).
(11) Remove differential housing mounting bolts
(Fig. 4).
(12) Lower axle from the vehicle.
Possible Causes
1. Overloading.
2. Erratic clutch operation.
3. Ice-spotted pavement.
4. Improper adjustments.
1. Insufficient lubricant.
2. Improper ring gear and pinion
adjustment.
3. Unmatched ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
5. Loose pinion bearings.
6. Loose differential bearings.
7. Mis-aligned or sprung ring gear.
8. Loose differential bearing cap
bolts.
9. Housing not machined properly.

INSTALLATION

(1) Raise axle into position.
(2) Install axle mounting bolts and tighten nuts to
95 N·m (70 ft. lbs.).
(3) Install suspension crossmember and bolts.
Tighten crossmember nuts to 102 N·m (75 ft. lbs.).
(4) Install front propeller shaft with reference
marks aligned (Fig. 5) and tighten bolts to 115 N·m
(85 ft. lbs.).
(5) Install exhaust crossover.
(6) Install axle half shafts.
(7) Check the differential fluid level and add fluid
if necessary.
(8) Install tire and wheel assemblies.
(9) Remove support lower the vehicle.

ADJUSTMENTS

Ring gear and pinion are supplied as matched sets
only. The identifying numbers for the ring gear and
FRONT AXLE - C205F
Correction
1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Replace gears and examine
remaining parts for damage.
4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
1. Fill differential with the correct
fluid type and quantity.
2. Check ring gear and pinion
contact pattern.
3. Replace gears with a matched
ring gear and pinion.
4. Replace ring gear and pinion.
5. Adjust pinion bearing pre-load.
6. Adjust differential bearing
pre-load.
7. Measure ring gear run-out.
Replace components as necessary.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Replace housing.
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