Dodge Sprinter 2006 Manual page 752

3 - 12 REAR AXLE
REAR AXLE
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - DRAIN AND FILL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 19
SHAFT-AXLE SINGLE REAR WHEEL
REMOVAL-SINGLE REAR WHEEL
INSTALLATION-SINGLE REAR WHEEL
BEARING/SEAL-AXLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
SHAFT-AXLE DUAL REAR WHEELS
REMOVAL-DUAL REAR WHEEL
INSTALLATION-DUAL REAR WHEEL
BEARING/SEAL-AXLE HUB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
REAR AX LE
DIAGNOSIS AND TESTING
NOTE: Axle seals, axle bearings, pinion seals and
differential cover are the only serviceble compo-
nents. If differential is damaged/noisy the axle must
be replaced.
GEAR NOISE
Axle gea r n oise ca n be ca u sed by in su fficien t lu br i-
ca n t , in cor r ect ba ckla sh , in cor r ect pin ion dept h , t oot h
con t a ct , wor n /da m a ged gea r s, or t h e ca r r ier h ou sin g
n ot h a vin g t h e pr oper offset a n d squ a r en ess.
Gea r n oise u su a lly h a ppen s a t a specific speed
r a n ge. Th e n oise ca n a lso occu r du r in g a specific t ype
of dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a -
t ion , deceler a t ion , coa st , or con st a n t loa d.
Wh en r oa d t est in g, fir st wa r m -u p t h e a xle flu id by
dr ivin g t h e veh icle a t lea st 5 m iles a n d t h en a cceler-
a t e t h e veh icle t o t h e speed r a n ge wh er e t h e n oise is
t h e gr ea t est . Sh ift ou t -of-gea r a n d coa st t h r ou gh t h e
pea k-n oise r a n ge. If t h e n oise st ops or ch a n ges
gr ea t ly:
• Ch eck for in su fficien t lu br ica n t .
• In cor r ect r in g gea r ba ckla sh .
• Gea r da m a ge.
Differ en t ia l side gea r s a n d pin ion s ca n be ch ecked
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se
REAR AX LE
TABLE OF CONTENTS
page
DIFFERENTIAL
. . 13
. . . . . . . . . . 23
. . . . . . . 24 BEARINGS-DIFFERENTIAL CASE
SEAL-PINION
. . . . . . . . . . . . 27
. . . . . . . . 28 GEAR-PINION/RING
n oise du r in g st r a igh t -a h ea d dr ivin g wh en t h e gea r s
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i-
cle t u r n s. A wor n pin ion sh a ft ca n a lso ca u se a sn a p-
pin g or a kn ockin g n oise.
BEARING NOISE
a ll pr odu ce n oise wh en wor n or da m a ged. Bea r in g
n oise ca n be eit h er a wh in in g, or a gr owlin g sou n d.
n oise ch a n ges on ly wit h veh icle speed. P in ion bea r in g
n oise will be h igh er pit ch ed beca u se it r ot a t es a t a
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en -
t ia l. If bea r in g n oise occu r s, t h e r ea r pin ion bea r in g
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is
h ea r d du r in g a coa st , t h e fr on t pin ion bea r in g is t h e
sou r ce.
n oise. Differ en t ia l bea r in g n oise is sim ila r t o pin ion
bea r in g n oise. Th e pit ch of differ en t ia l bea r in g n oise
is a lso con st a n t a n d va r ies on ly wit h veh icle speed.
wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
Tu r n t h e veh icle sh a r ply t o t h e left a n d t o t h e r igh t .
Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DISASSEMBLY
DISASSEMBLY-SINGLE REAR WHEEL
DISASSEMBLY-DUAL REAR WHEEL
ASSEMBLY
ASSEMBLY-SINGLE REAR WHEEL
ASSEMBLY-DUAL REAR WHEEL . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
Th e a xle sh a ft , differ en t ia l a n d pin ion bea r in gs ca n
P in io n be a rin g s h a ve a con st a n t -pit ch n oise. Th is
D iffe re n tia l be a rin g s u su a lly pr odu ce a low pit ch
Ax le s h a ft be a rin g s pr odu ce n oise a n d vibr a t ion
VA
page
. . . . . 32
. . . . . . . 33
. . . . . . . . 34