Suspension - Front (Leaf): Removal & Installation Dodge Cab & Chassis Dakota

INSTALLATION (LEFT SIDE)

1. Using Bar (D-354-4 ), Installer (D-354-2 ) and Puller (C-637 ), install inner axle shaft bearing. see scheme 4 Using bar and Adapter (D-354-3 ), install and seat inner axle shaft. Insert "C" lock in recessed groove in shaft. Position shift collar on splined end of inner axle shaft.
2. Using Installer (D-360 ) and Handle (C-4171 ), install outer axle shaft bearing and seal. Using handle and Installer (D-328 ), install bearing into intermediate axle shaft. Install intermediate axle shaft through seal into housing without damaging shaft seal.
3. Install disconnect housing assembly and gasket while guiding shift fork into groove of shift collar. Install and tighten disconnect housing assembly bolts.
4. To complete installation, reverse removal procedure. Apply RTV sealant to edge of grease cap. Apply 1/16-3/32" bead of silicone rubber sealant along bolt circle of differential housing cover before installing.
5. Install inner pad anti-rattle spring on top of retainer spring plate. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-52211-S24595123782001011600000) table at end of article.

INSTALLATION (RIGHT SIDE)

1. Position seal on stone shield with seal lip facing toward shaft spline. Install axle shaft into housing without damaging differential seal at side gear.
2. To complete installation, reverse removal procedure. Apply RTV sealant to edge of grease cap. Inner pad anti-rattle spring must be installed on top of retainer spring plate. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS & INSPECTION»(ref-52211-S11566953512001011600000) . Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-52211-S24595123782001011600000) table at end of article.

REMOVAL (MODEL 60)

1. Block brake pedal in up position. Raise and support vehicle. Remove wheel. Remove rotor. See «WHEEL BEARINGS R & I»(ref-52211-S16447838072001011600000) .
2. Remove brake splash shield, brake adapter and spindle-to-steering knuckle nuts and washers. Remove spindle from steering knuckle. Remove axle shaft, Bronze spacer, seal and slinger from housing.

INSTALLATION

1. Install axle shaft. Place Bronze spacer on axle shaft with chamfered edge facing inward. To complete installation, reverse removal procedure.
2. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-52211-S24595123782001011600000) table at end of article.

REMOVAL (MODEL 44 AXLE)

1. Raise and support vehicle. Remove wheel. Remove brake rotor. See WHEEL BEARING R & I. Remove caliper adapter from steering knuckle.
2. Remove and discard 6 nuts and washers from spindle-to-knuckle attaching bolts. Remove brake splash shield. Using soft-faced mallet, strike spindle lightly to loosen from knuckle.
3. Place spindle in soft-jawed vise. DO NOT clamp bearing surfaces. Remove seal. On right side, use Puller (D-131 ) to remove needle bearings from right spindle. Remove axle shaft. Remove seal from axle shaft.
4. Remove cotter pin and nut from tie rod end. Loosen clamp bolt nut. Using Puller (C-3894-A ), remove tie rod end from steering knuckle. Mark tie rod end and tie rod for reassembly reference. Remove tie rod end.
5. On left side, remove cotter pin and nut from drag link. Using Puller (C-4150 ), remove drag link from steering knuckle arm and steering gear arm. Lower drag link from vehicle. Remove nuts and cone washers from steering knuckle arm. Tap steering knuckle arm to loosen. Remove steering knuckle arm.
6. On both sides, remove cotter pin from upper ball joint nut. Remove upper and lower ball joint nut. Discard lower ball joint nut. Using brass drift and hammer, separate steering knuckle from axle housing yoke. Using Sleeve Tool (C-4169 ), remove and discard sleeve from upper ball joint yoke on axle housing.
7. Position steering knuckle upside-down in vise. Using Snap Ring Pliers (C-4020 ), remove snap ring from lower ball joint. Using Ball Joint Stand (C-4212-L ), Adapter (D-150-3 ), Screw (D-150-2 ) and Block (D-150-1 ), press lower ball joint from steering knuckle. (Scheme 8) Reposition stand. Press upper ball joint from steering knuckle.
8. Replace ball joints if any looseness or play exists. Clean all components with solvent, and dry with compressed air. Inspect all parts for burrs, chips, wear or cracks. Replace as required.

Scheme 8

Scheme 9

1. Place steering knuckle in vise. Press ball joints into position with stand and components. (Scheme 9) Install new boots on ball joints. Remove steering knuckle from vise. Insert new sleeve into upper ball joint yoke of axle housing, allowing 2 threads to be exposed at top of housing.
2. Place steering knuckle on axle housing yoke. Install and tighten NEW lower ball joint nut. Using Sleeve Tool (C-4169 ) and torque wrench, tighten upper ball joint yoke sleeve to 40 ft. lbs. (54 N.m). Install upper ball joint nut, and tighten to 100 ft. lbs. (136 N.m).
3. Align cotter pin hole in stud with slot in castellated nut. Tighten nut to align hole and slot. DO NOT loosen. Insert cotter pin. Install steering knuckle arm, cone washer and drag link on left side of vehicle.
4. Install tie rod ends. Apply multipurpose grease to seal lip. Install seal on stone shield with seal lip facing axle shaft spline. Install right axle shaft into housing without damaging seal.
5. On left axle shaft, remove disconnect housing assembly. Install shaft. Install disconnect housing assembly. Using Installer (D-360 ) and Handle (C-4171 ), install new needle bearings in RIGHT spindle.
6. Using Installer (D-155 ) and handle, install new brake hub seals. Grease full circumference of seal and spindle thrust surface. Install new spacer on axle shaft. Install spindle and brake splash shield.
7. To complete installation, reverse removal procedure. Ensure inboard brake pad anti-rattle spring is on top of retainer spring plate. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-52211-S24595123782001011600000) table at end of article.

REMOVAL (MODEL 60 AXLE)

1. Remove axle shafts. See «AXLE SHAFTS R & I»(ref-52211-S32442895582001011600000). Remove cotter pin and nut from tie rod end. Loosen clamp bolt nut. Using Puller (C-3894-A ), remove tie rod end.
2. On left side, remove cotter pin and nut from drag link. Using Puller (C-4150 ), remove tie rod end from steering knuckle arm. Disconnect drag link from steering knuckle. Remove steering knuckle arm bolts and arm.
3. On left side, remove upper steering knuckle cap, and discard gasket. Remove spring and upper socket sleeve. Remove lower steering knuckle cap bolts and cap. To separate steering knuckle from axle housing, swing steering knuckle outward at bottom while lifting up and off upper socket pin.
4. Using Socket (D-192 ), loosen and remove upper socket pin. Remove seal. Using Ball Joint Stand (C-4212-L ) and Adapters (C-4366-1 and C-4366-2 ), press lower ball socket assembly from axle housing. (Scheme 10)
5. Clean all components with solvent, and dry with compressed air. Inspect components for burrs, chips, wear, flat spots or cracks. Replace as necessary.

Scheme 10

Scheme 11

1. Apply multipurpose lubricant to the lower ball socket. Using Ball Joint Stand (C-4212-L ) and Adapters (C-4366-3, C-4366-4 and C-4366-5 ), press seal and lower bearing race into axle housing. (Scheme 11) Replace adapters. Install lower bearing and seal into housing.
2. Using Socket (D-192 ) and torque wrench, install and tighten upper socket pin. Install seal over pin. Position steering knuckle over socket pin. Fill lower socket cavity with multipurpose lubricant. Install lower steering knuckle cap.
3. Apply generous amount of multipurpose lubricant to upper socket pin. Align upper socket sleeve in keyway of steering knuckle, and slide into position. (Scheme 12) Install new gasket over upper steering knuckle studs. Position upper socket spring over sleeve. Install steering knuckle cap.
4. On left side, connect drag link to steering knuckle. Install nut, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-52211-S24595123782001011600000) table at end of article. Install cotter pin.
5. To complete installation, reverse removal procedure. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION.

Scheme 12

REMOVAL

1. Turn shift knob to ENGAGE position. Apply downward pressure to face of shift knob, and remove 3 shift knob retaining screws nearest to flange. With an outward pull, remove shift knob from mounting base.
2. Remove snap ring from axle shaft. Remove cam screws and lock washers from mounting base flange. Separate and remove locking hub assembly from rotor hub. Remove and discard gasket.

1. Lightly lubricate parts with multipurpose lubricant. Position new gasket and locking hub onto rotor hub. Install attaching cam screws and lock washers. Tighten to 30-40 ft. lbs. (41-54 N.m). Install axle shaft snap ring.
2. Position shift knob on mounting base. Align splines by pushing inward on shift knob. Turn clockwise to lock in position. Install and tighten 3 shift knob retaining screws.

1. Raise and support vehicle. Remove wheel. Remove caliper retainer and anti-rattle spring assemblies. Remove caliper from rotor. Wire caliper aside. DO NOT allow caliper to hang by hose.
2. Remove inner brake pad. Remove grease cap and driving hub snap ring. Remove driving hub and retaining spring. Using Socket (C-4170-A ), remove bearing lock nut.
3. Remove retaining washer and adjusting nut. Remove rotor. Outer bearing and retainer spring will also slide out. Pry inner seal from hub. Remove bearing.

1. Lubricate and install inner bearing. Using Seal Installer (D-359 ) and Handle (C-4171 ), install inner seal. Install rotor and outer wheel bearing.
2. Install the adjusting nut. Adjust wheel bearings. Refer to «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION. Apply RTV sealer on edge of grease cap. Install grease cap. Position inner pad on adapter, with shoe flanges in adapter guides.
3. Slide caliper into position in adapter and over rotor. Align caliper on machined faces of adapter without pulling dust boot from groove on caliper as piston and boot are slid over inner pad.
4. Install anti-rattle springs and retaining clips. Tighten to 15 ft. lbs. (20 N.m). Inner pad anti-rattle spring must be installed on top of retainer spring plate.

MODEL 60 AXLE R & I

1. Block brake pedal in up position. Raise and support vehicle. Remove wheel. Remove caliper-to-adapter Allen screw. Tap adapter lock and spring from between brake caliper and adapter. Separate brake caliper from adapter.
2. Wire caliper aside. DO NOT allow brake caliper to hang by hose. Inner pad will remain on adapter. Remove hub cap. Using Snap Ring Pliers (C-4020 ), remove snap ring. Remove flange nuts and lock washers. Remove drive flange. Discard gasket. Remove locking hub (if equipped). See «LOCKING HUB R & I»(ref-52211-S01109246562001011600000)
3. Straighten tangs on lock ring. Using Socket (DD-1241-JD ), loosen outer lock nut. Remove lock nut, lock ring, inner lock nut and outer bearing. Slide hub and rotor from spindle knuckle. Remove oil seal and inner bearing.
4. Clean the wheel bearings. Inspect for damage. If necessary, replace bearings and races as an assembly. To install, reverse removal procedure. Inner pad anti-rattle spring must be installed on top of retainer spring plate. Adjust wheel bearings. See «WHEEL BEARING ADJUSTMENTS»(ref-52211-S11566953512001011600000) & INSPECTION.