Dodge R1500 1999 Service Manual page 448

ring gear backlash will be checked with same teeth meshed. Rotate ring
gear to point of minimum ring gear backlash.
6) Loosen right adjuster (viewed from rear of axle housing)
and tighten left adjuster until ring gear backlash is .003-.004" (.08-
.10 mm) with each adjuster tightened to 120 INCH lbs. (14 N.m).
7) Rotate pinion back and forth 5-10 times to ensure proper
seating of differential bearings. Ensure ring gear backlash is still
as specified. Tighten bearing cap bolts to specification. See TORQUE
SPECIFICATIONS table.
8) Using adjuster rotator, tighten right adjuster to 75 ft.
lbs. (102 N.m). Rotate pinion back and forth 5-10 times to ensure
proper seating of differential bearings. Continue to tighten right
adjuster until torque remains constant at 75 ft. lbs. (102 N.m).
9) Recheck ring gear backlash at point of minimum ring gear
backlash. If ring gear backlash is not .005-.008" (.13-.20 mm),
increase torque on right adjuster, and seat differential bearings by
rotating pinion. Continue to tighten right adjuster until ring gear
backlash is correct.
10) Tighten left adjuster to 75 ft. lbs. (102 N.m). Rotate
pinion back and forth 5-10 times to ensure proper seating of
differential bearings. Continue to tighten left adjuster until torque
remains constant at 75 ft. lbs. (102 N.m).
11) Check ring gear backlash every 90 degrees to check ring
gear backlash variation. Ring gear backlash variation should not
exceed .003" (.08 mm). For example, if ring gear backlash is .005" (.
15 mm) at minimum point, ring gear backlash should not exceed .008" (.
20 mm) anywhere on ring gear.
12) With adjustments completed, install adjuster locks.
Ensure teeth on adjuster lock engages with hole in adjuster. Install
and tighten adjuster lock bolt to specification. See TORQUE
SPECIFICATIONS table.
FINAL INSPECTION & ASSEMBLY
1) With pinion bearing preload and ring gear backlash
properly adjusted, check gear tooth pattern contact. See GEAR TOOTH
CONTACT PATTERNS article in GENERAL INFORMATION.
2) To check side gear clearance, install axle shafts into
axle housing and side gears. Install clip on end of axle shaft. Pull
axle shaft outward, ensuring clip fully seats in counterbore on side
gear.
NOTE: If replacing side gears or side gear thrust washers, check
side gear clearance with axle shaft installed in axle
housing. Check side gear clearance on both side gears.
3) Install equal thickness feeler gauges on each side of side
gear, next to hub of side gear. See Fig. 4. This is side gear
clearance.
Fig. 4: Checking Side Gear Clearance
Courtesy of Chrysler Corp.
4) If no side gear clearance exists, proceed to step 8). If