Dodge R1500 1999 Service Manual page 415

original pinion depth shims. Replace shims with NEW shims of same
thickness.
4) If only pinion and ring gear are being replaced and
original axle housing is used, note pinion depth variance marking on
old pinion and replacement pinion.
5) Using etched markings and pinion depth shim adjustment
chart, determine amount to be added or subtracted from thickness of
original pinion depth shims. See Fig. 4. For example, if etched
marking is +4 on original pinion and -4 on replacement pinion,
thickness of pinion depth shims should be increased by .008" (.20 mm).
NOTE: When using pinion depth shim adjustment chart, if result is a
negative (-) reading, subtract this amount from thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is positive (+), add this amount to thickness of
pinion depth shim pack to obtain thickness of correct shim.
If result is zero, this will be nominal standard pinion depth
setting and no shims are required. When using pinion depth
shim adjustment chart, thickness of original pinion depth
shim pack must be accurately determined. If original pinion
depth shim pack dimension cannot be accurately determined,
pinion depth gauge set must be used to properly determine
pinion depth setting. Pinion depth gauge set must also be
used if using replacement axle housing. Proceed to
DETERMINING PINION DEPTH USING PINION DEPTH GAUGE SET.
NOTE: If slinger is used, slinger thickness must also be included
in pinion depth shim pack.
Fig. 4: Pinion Depth Shim Adjustment Chart
Courtesy of Chrysler Corp.
Determining Pinion Depth Using Pinion Depth Gauge Set
1) Use Pinion Depth Gauge Set for all axle models. Place
master pinion block in pinion bore of axle housing. See Fig. 5.
Install discs on arbor. Install arbor in axle housing, with discs
positioned in differential bearing bores. See Fig. 5.
2) Install pinion height block on top of master pinion block,
against arbor. Place gauge block with dial indicator on lowest step of