Chrysler RAM TRUCK 2500 1994 Service Manual page 129

3 • 22 REAR SUSPENSION AND AXLE
•
the axle shaft is not contacting the pinion gear mate
shaft, the side gear clearance is acceptable.
(4) I f clearance is more than 0.005 inch (axle shaft
not contacting mate shaft), record the side gear clear­
ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick­
ness to the recorded side gear clearance. The sum of
gear clearance and washer thickness will determine
required thickness of replacement thrust washer
(Fig. 30).
SIDE GEAR CLEARANCE 0.007
THRUST WASHER THICKNESS
+ 0 . 0 3 3
TOTAL 0.040
I
• 0.040
REPLACEMENT WASHER THICKNESS
- 0 . 0 3 7
NEW SIDE GEAR CLEARANCE
0.003
J9203-31
Fig. 30 Side Gear Calculations
In some cases, the end of the axle shaft will move
and contact the mate shaft when the feeler gauge is
inserted. The C-clip lock is preventing the side gear
from sliding on the axle shaft.
(5) I f there is no side gear clearance, remove the
C-clip lock from the axle shaft. Use a micrometer to
measure the thrust washer thickness. Record the
thickness and re-install the thrust washer. Assemble
the differential case without the C-clip lock installed
and re-measure the side gear clearance.
(6) Compare both clearance measurements. I f the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) I f clearance is 0.012 inch (0.305 mm) or greater,
both side gears must be replaced (matched set) and
the clearance measurements repeated.
(8) I f clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
RING G E A R T E E T H CONTACT PATTERN
ANALYSIS
The ring gear teeth contact patterns will show i f
the pinion gear depth shim(s) have the correct thick­
ness. I t will also show i f the ring gear backlash has
been adjusted correctly. The backlash must be main­
tained within the specified limits until the correct
teeth contact patterns are obtained.
• Excessive backlash is corrected by moving the ring
gear teeth closer to the pinion gear teeth
• Insufficient backlash is corrected by moving the
ring gear away from the pinion gear
(1) Apply yellow ferrous (iron) oxide compound to
both drive and coast sides of ring gear teeth.
(2) Rotate the ring gear one complete revolution i n
both directions.
(3) Note patterns i n compound. Refer to (Fig. 31)
for interpretation of contact patterns and adjust ac­
cordingly.
(4) Install the axle shafts. Refer to Axle Shaft I n ­
stallation within this group.
(5) Install the housing cover. Refill the differential
with lubricant. Refer to Axle Shaft Installation.
(6) Install the RWAL/ABS brake speed sensor and
cover onto the axle housing. Tighten the sensor to 13
N-m (10 ft. lbs.) torque.