Dodge D150 1990 Service Manual page 134

• FRONT SUSPENSION 2 - 65
(28) Remove t h e o i l slinger, t h e shaft front b e a r i n g
and the " p r e l o a d " torque shims (Fig. 25). Record t h e
thickness o f t h e shims. T h i s w i l l s a v e t i m e i f t h e y
s h o u l d b e c o m e m i s p l a c e d .
(29) Use a n appropriate tool t o force the drive p i n -
i o n gear shaft ( w i t h t h e rear bearing) from t h e dif-
ferential h o u s i n g bore (Fig. 25).
(30) Use Removal Tool D-158 and Handle Tool C-
4171 t o remove t h e drive p i n i o n gear shaft outer
(front) b e a r i n g cup f r o m the differential housing bore
(Fig. 25).
(31) Use Removal Tool D-162 and Handle Tool C-
4171 to remove t h e d r i v e p i n i o n gear shaft i n n e r
(rear) b e a r i n g cup from the differential housing bore
(Fig. 25).
(32) Remove t h e d r i v e p i n i o n gear depth shims
from t h e differential housing bore (Fig. 25). Record
the thickness o f the depth shims.
(33) Remove t h e i n n e r (rear) bearing f r o m t h e
drive p i n i o n gear shaft w i t h Removal Tool DD-914-P,
Adapter R i n g Tools DD-914-9 a n d Plate Tools D D -
914-37 (or Tool C-293-P a n d Adapter Tools C-293-37).
(34) Clamp t h e differential case i n a vise equipped
w i t h soft jaws. Use a p i n punch t o force t h e p i n i o n
gear mate shaft lock p i n f r o m t h e differential case
bore (Fig. 26).
DIFFERENTIAL
Fig. 26 Pinion Gear Mate Shaft Lock Pin Removal
(35) Remove the d i f f e r e n t i a l p i n i o n gear mate shaft
f r o m the d i f f e r e n t i a l case bores, remove the differen-
t i a l p i n i o n gears and remove the t h r u s t washers (lo-
cated adjacent t o t h e differential case i n t e r n a l
surface) f r o m t h e d i f f e r e n t i a l case.
(36) Remove t h e d i f f e r e n t i a l side gears a n d t h e
t h r u s t washers (located adjacent t o t h e differential
case i n t e r n a l surface) f r o m the differential case.
(37) Remove the d i f f e r e n t i a l case from the vise.
(38) Remove the bearings f r o m the differential case
w i t h Removal Tool DD-914-P, Adapter R i n g Tools
DD-914-8, Plate Tools DD-914-62, Screw Extension
Tool DD-914-7, B u t t o n Tool DD-914-42 a n d a vise
(Fig. 27).
Use c a r e a n d e n s u r e t h a t t h e a d a p t e r r i n g s a r e
s i t u a t e d so t h a t t h e y d o n o t cause f o r c e t o b e ex-
e r t e d o n t h e b e a r i n g r a c e .
Fig. 27 Differential Bearing Removal
(39) Remove t h e differential bearing shims from
each of t h e differential case hubs a n d m a r k t h e m
( w i t h hub identity) for assembly reference. Record
the thickness o f the shims.
(40) Remove the seals from the axle shaft tubes.
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
(Fig. 25) w i t h a n appropriate cleaning solvent and,
w i t h t h e exception of t h e bearings, d r y w i t h com-
pressed air.
D o n o t s t e a m c l e a n t h e d i f f e r e n t i a l c o m p o -
n e n t s .
(2) To clean the axle shaft tubes, insert a stiff w i r e
into each tube, attach a clean cloth to the w i r e a t the
differential housing opening and w i t h d r a w t h e w i r e
(and cloth) f r o m t h e housing outward t h r o u g h t h e
tube.
(3) Inspect t h e differential bearings and t h e drive
p i n i o n gear shaft bearings, and the differential case
and housing (Fig. 25):
• the differential bearings and the drive p i n i o n gear
shaft outer (front) and inner (rear) bearings and cups
should have a smooth appearance w i t h no broken/
dented surfaces on t h e bearing rollers or t h e roller
contact surfaces;
• the bearing races m u s t not be distorted or cracked;
I f a d i f f e r e n t i a l b e a r i n g m u s t b e r e p l a c e d , t h e
c u p a n d t h e b e a r i n g m u s t b e r e p l a c e d as a
" m a t c h e d s e t " o n l y .
• a l l t h e machined contact surfaces i n t h e differen-
t i a l housing a n d on t h e differential bearing caps
should be smooth and w i t h o u t any raised edges;