For example, if your vehicle is jerking and throwing unusual smoke, you may suspect tens of things, if not hundreds. However, the repair manual will give you a great pinpointing technique so you can remove the guesswork from the diagnosing process. As a conclusion, we want to stress the importance of the Dodge Dakota service manual pdf. As mentioned above, the manual is created for both new and experienced owners so they could remove extra hustle and troubles from their repair process. More importantly, the Dodge service manual provides great technical and repair knowledge that you may use in the future.
It is always great to rely on your knowledge and skills to be successful in any situation. Your email address will not be published. In general, the repair manual can beneficial for the following reasons: To handle emergency situations. Related Posts. Posted in Blog. Leave a Reply Cancel reply Your email address will not be published. Best Car Cover For Snow.
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Dodge - Dakota - Sales Brochure - - Tighten the cover bolts in a criss-cross pattern to 47 Nzm 35 ft. Note the torque for installation reference. It must be known to properly adjust the pinion gear bearing preload torque after seal installation.
The convex side of the washer must face outward. Install a new nut on the pinion gear. Tighten the nut only enough to remove the shaft end play. Clean the seal contact surface in the housing bore.
Do not over-tighten, or loosen and then re-tighten the nut. Do not exceed the bearing preload torque. The collapsible preload spacer on the pinion shaft will have to be replaced. The bearing preload torque will be re-adjusted afterward. Required preload torque is the amount recorded during removal plus an additional 0.
Tighten the shaft nut in very small increments. Remove the axle shaft C-clip lock from the axle shaft Fig. Remove the housing cover. Remove the lock screw and pinion shaft from the differential case Fig. Use care to prevent damage to the axle shaft bearing, which will remain in the axle shaft tube.
The normal appearance from roller bearing contact will be a dull gray surface area that could appear slightly dented. Separate ball stud from knuckle with Remover CA. Remove as necessary. The flat side of the installation tool must face the seal. Insert the axle shaft and engage the splines with the side gear.
Use care to prevent the shaft splines from damaging the axle shaft seal lip. Push the axle shaft outward to seat the C-clip lock. Install through the thrust washers and pinion gears. Align the hole in the shaft with the lock screw hole. Install the lock screw with Loctite on the threads. Tighten the screw to 11 Nzm 8 ft.
Refer to the Drain and Refill in this section. Fill the differential housing with lubricant. Refer to the Specifications chart for the type and the quantity. Install the fill hole plug. Install nut and tighten to Nzm ft. Install new cotter pin. Side play and runout checks taken during disassembly will be very useful in reassembly.
Position a screwdriver or pinch bar between left side of axle housing and case flange Fig. Use a prying motion to determine if any side play exists. There should be no side play. Mark the ring gear and the differential case at the areas of maximum runout. The ring gear runout should not exceed 0. If the runout exceeds 0. The marking on the differential case will be very useful later during the differential case runout.
Otherwise, use threaded adjuster to remove the side play before measuring the ring gear runout. Place the indicator plunger at a right angle 90 to the ring gear Fig. The plunger should exert a slight force against the gear face. Observe the dial indica-. Loosen the bolts, but do not remove the bearing caps. Remove the bearing caps Fig. Each differential bearing cup and threaded adjuster must be kept in their respective bear-.
This will damage the front bearing rollers and bearing cup. The front bearing and cup must be replaced. Discard the bearing collapsible spacer. Remove and record the pinion gear depth shims.
Use a vise equipped with soft jaws brass. The bolts have left-hand threads. Use a hammer and a brass drift to force the ring gear loose from the case pilots. Remove the ring gear. If the runout exceeds the amount, replace the differential case.
You can reduce excessive ring gear runout by positioning the ring gear runout mark degrees opposite the flange runout mark. Remove the differential case from the differential housing. Install the case with the bearing cups and the threaded adjusters close to their original position.
Tighten the bolts lightly. Use Wrench C to thread both adjusters inward. Remove all side play. The plunger should contact the ring squarely between the outer edge and the gear bolt holes Fig. Observe the dial indicator pointer. Mark the area of maximum flange runout. The differential case flange. Allow the bearings to either air dry or dry them with a lint-free cloth. Dry the other components with compressed air. Replace bearings and cups if either is galled, worn, cracked, or damaged.
Replace any gear that is worn, cracked or chipped. Replace the case if cracked or damaged. Polish each axle shaft with No. This can remove slight surface damage. Do not reduce the diameter of the axle shaft seal contact surface. When polishing, the crocus cloth should be moved around the circumference of the shaft not in-line with the shaft. When replacing a drive pinion gear bearing, always replace the bearing and cup as a matched set only.
Replace them if necessary. Position the gears in the differential case counterbores. Mesh the pinion gears with the side gears. Ensure that the pinion gears are exactly degrees opposite each other. Align these components with the mate shaft bores in the case. Use an Arkansas stone or fine file to remove any sharp areas from the chamfered inside diameter. The temperature should not exceed C F. Do not use a torch to heat the ring.
Alternately and evenly tighten each bolt to 95 Nzm 70 ft. Place a piece of 0. Position the bearing caps on the arbor tool. Install the bolts. Tighten the cap bolts to 14 Nzm 10 ft. The depth shim s fit must be snug but not tight drag friction of a feeler gauge blade.
Tighten the nut to seat the pinion bearings in the housing Fig. Allow the sleeve to turn several times during the tightening to prevent brinelling the bearing cups or the bearings.
The required thickness of the depth shim s is determined according to the following information. Lubricate the pinion gear front and rear bearings with gear lubricant. Re-tighten the compression nut tool to 1 to 3 Nzm 15 to 25 in. Rotate the pinion gear several complete revolutions to align the bearing rollers. Depth shims are available in 0.
The numbers represent thousandsof-an-inch deviation from the standard. If the number is - negative , add that value to the required thickness of the depth shim s. If the number is 0, no change is necessary. Install the rear bearing with Installer C Fig. Be sure the contact surfaces are clean and without foreign particles. Install the new collapsible spacer at the end of the pinion gear. Install the pinion gear front bearing. It is necessary to use the tools above to correctly seat the front bearing on the drive pinion gear shaft Fig.
The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. Install the Belleville washer.
Install the pinion nut. Initially tighten the drive pinion gear shaft nut enough to remove the bearing end play. While tightening, rotate the pinion shaft to ensure the bearing rollers are correctly seated Fig.
Rotate the pinion several complete revolutions both directions to additionally seat the bearing rollers. If the preload torque varies during rotation of the shaft, there is an internal binding that must be corrected before final assembly. The differential will be unacceptable for use if the final nut torque is less than Nzm ft. If the preload torque is not within the specified range this is also unacceptable.
If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will have to be repeated. The correct bearing preload torque is 1 to 2 Nzm 10 to 20 in. This torque value is with replacement bearings and pinion nut tightened to a minimum of Nzm ft.
When using original pinion rear bearing and a replacement front bearing. The correct pre-. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing. Tighten the upper bolts to 14 Nzm 10 ft. Tighten the lower bolts finger-tight until the bolt head is lightly seated.
Ensure accurate bearing cup responses to the adjustments. Maintain the gear teeth engaged meshed as marked. The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth. Do this five to ten times each time the threaded adjusters are adjusted. Allow some ring gear backlash approximately 0. Seat the bearing cups with the procedure described above. Position the plunger against the drive side of a ring gear tooth.
Measure the backlash at 4 positions 90 degrees apart around the ring gear. Locate and mark the area of minimum backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed. Obtain backlash of 0. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 95 Nzm 70 ft.
The range of backlash is 0. Continue increasing the torque at the right-side threaded adjuster until the specified backlash is obtained. The left-side threaded adjuster torque should have approximately 95 Nzm 70 ft. If the torque is considerably less, the complete adjustment procedure must be repeated. Seat the bearing rollers with the procedure described above.
Do this until the torque remains constant. Ensure the lock finger is engaged with the adjuster hole. Tighten the lock screws to 10 Nzm 90 in. One side gear can have an acceptable clearance and other side gear to have an unacceptable clearance. If it necessary to replace a side gear, replace both gears as a matched set. If necessary, refer to the installation located within this group. Insert a matched pair of feeler gauge blades between the gear and differential housing on opposite sides of the hub Fig.
Determine if the shaft is contacting the pinion gear mate shaft. Do not remove the feeler gauges, inspect the axle shaft with the feeler gauge inserted behind the side gear. If the end of the axle shaft is not contacting the pinion gear mate shaft, the side gear clearance is acceptable. Remove the thrust washer and measure its thickness with a micrometer.
Add the washer thickness to the recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness of replacement thrust washer Fig. The C-clip lock is preventing the side gear from sliding on 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.
If the difference is less than 0. The sum will determine the required thickness of the replacement thrust washer. It will also show if the ring gear backlash has been adjusted correctly. The backlash must be maintained 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.
Refer to Axle Shaft Installation in this group. Refill the differential with lubricant. Refer to Axle Shaft Installation.
Semi-floating, hypoid Lubricant Axle Ratio Case Flange Runout Ring Gear Diameter Pinion Bearing Preload Lower Bolts Lower Suspension Arm Front Nut Rear Nut Ball Stud Nut Stabilizer Bar Clamp Bolt Link Nut Support Bracket Bolts Lower Bolt Lower Suspension Arm Front Bolt Rear Bolt Axle Nut Housing Bolts Support Bolts Cover Bolt Bearing Cap Bolt Ring Gear Bolt The forward end of the springs are mounted to the frame rail hangers through rubber bushings.
The bushings isolate road noise as the springs move. The rearward end of the springs are attached to the frame by the use of shackles. Again the spring and shackles use rubber bushings to isolate road noise. The shackles allow the springs to change their length as the vehicle moves over various road conditions.
The spring and axle travel is limited through the use of rubber bumpers mounted on the frame. Suspension components that use rubber bushings should be tightened with the vehicle at the normal height. The springs are attached to the axle pads with Ubolts and plates.
The springs use a center bolt that aligns and holds the spring leafs in position. The bolt is also used to locate the spring assembly to the axle pad which is welded to the axle shaft tubes.
The top of the shock absorbers are bolted to the frame crossmember. The bottom of the shocks are bolted to the axle bracket. A small, gear ratio identification tag is attached to the housing cover. The rear wheel anti-lock RWAL brake speed sensor is attached to the top of the differential housing Fig. A seal is located between the sensor and the wire harness connector.
The seal must be in-place when the wire connector is connected to the sensor. The RWAL brake exciter ring is press-fitted onto the differential case against the flange. They also have two steel axle shaft tubes that are pressed into and welded to the differential housing.
The outer end is 3. Both axle types are equipped with a remote vent fitting. When turning corners, the outside wheel must. In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite direc-. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed. A noise from the shock absorber or spring bushings can be produced if movement between the rubber bushings and the metal occurs.
This noise can usually be stopped by tightening the nuts. If the noise persists, inspect for damaged and worn bushings. Repair as necessary. The shock absorber bushings do not require any type of lubrication. Do not lubricate the bushings to reduce bushing noise.
Grease or mineral oil-base lubricants will deteriorate the bushing rubber. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston into and out of the cylinder four or five times. The action throughout each stroke should be smooth and even.
The spring eye and shock absorber bushings do not require any type of lubrication. Do not attempt to stop spring bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing rubber. If the vehicle is used for severe, off-road operation, the springs should be examined regularly. Check for broken and shifted components. A vehicle should always be loaded so the vehicle weight center-line is located immediately forward of the rear axle.
Correct vehicle loading provides proper front tire-to-road contact. This results in maximum vehicle handling stability and safety. Incorrect vehicle weight distribution can cause excessive tire wear, spring fatigue, and erratic steering. Refer to Spring and Shock Absorber Diagnosis chart for further information. Remove the shock absorber. Install the bolt and nut and tighten to 81 Nzm 60 ft. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange.
Make sure the spring center bolt is inserted in the pad locating hole Fig. If 2WD, ensure the parking brake cable guide is properly positioned. Install the spring eye bolt and nut Fig.
Tighten the spring eye nut fingertight. Install the bolt and nut Fig. Tighten the spring shackle eye nut finger-tight. Tighten the nuts until the washers are compressed against the spring bracket. Lower the vehicle until the springs are supporting the weight of the vehicle.
Tighten the Ubolt nuts Fig. If necessary, refer to the removal procedure. Insert a long drift or punch into the spring center bolt hole.
It may, however, be difficult for new users. This is why you need a Download Dodge Dakota manual. It covers everything from maintenance to troubleshooting to inspection to repair. Also known as a shop manual or a service manual, the manual is suitable for professionals as well since it contains not only basic how-to guides and information but also complex and advanced particulars.
With the manual by your side, you will be able to take care of emergencies on your own. It works as an assistant, telling you what to do when things go wrong. Plus, it can also help take care of future problems by giving you the opportunity to inspect your vehicle in a proper manner.
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