Chrysler Full-Size Trucks 1989-1996 Repair Guide

Front Wheel Bearings

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REMOVAL, REPACKING, & INSTALLATION



Before handling the bearings, there are a few things that you should remember to do and NOT to do.

Remember to DO the following:


Remove all outside dirt from the housing before exposing the bearing.
 
Treat a used bearing as gently as you would a new one.
 
Work with clean tools in clean surroundings.
 
Use clean, dry canvas gloves, or at least clean, dry hands.
 
Clean solvents and flushing fluids are a must.
 
Use clean paper when laying out the bearings to dry.
 
Protect disassembled bearings from rust and dirt. Cover them up.
 
Use clean rags to wipe bearings.
 
Keep the bearings in oil-proof paper when they are to be stored or are not in use.
 
Clean the inside of the housing before replacing the bearing.
 

Do NOT do the following:


Don't work in dirty surroundings.
 
Don't use dirty, chipped or damaged tools.
 
Try not to work on wooden benches or use wooden mallets.
 
Don't handle bearings with dirty or moist hands.
 
Do not use gasoline for cleaning; use a safe solvent.
 
Do not spin-dry bearings with compressed air. They will likely be damaged.
 
Do not spin dirty bearings.
 
Avoid using cotton, waste, or dirty cloths to wipe bearings.
 
Try not to scratch or nick bearing surfaces.
 
Do not allow the bearing to come in contact with dirt or rust at any time.
 

2-Wheel Drive Vehicles

See Figures 1, 2 and 3

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheel cover. Remove the wheel.
  4.  
  5. Remove the caliper from the disc and wire it to the underbody to prevent damage to the brake hose. See Brakes .
  6.  



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Fig. Fig. 1: Exploded view of 2WD front wheel and bearing assembly



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Fig. Fig. 2: Remove the 2WD front bearing using a suitable driver

  1. Remove the grease cap from the hub. Then, remove the cotter pin, nut lock, adjusting nut and flat washer from the spindle. Remove the outer bearing assembly from the hub.
  2.  
  3. Pull the hub and disc assembly off the wheel spindle.
  4.  



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Fig. Fig. 3: Press in the bearing races using a driver of suitable diameter-special factory tool shown

  1. Remove and discard the old grease retainer. Remove the inner bearing cone and roller assembly from the hub.
  2.  
  3. Clean all grease from the inner and outer bearing cups with solvent. Inspect the cups for pits, scratches, or excessive wear. If the cups are damaged, remove them with a drift.
  4.  
  5. Clean the inner and outer cone and roller assemblies with solvent and shake them dry. If the cone and roller assemblies show excessive wear or damage, replace them with the bearing cups as a unit.
  6.  
  7. Clean the spindle and the inside of the hub with solvent to thoroughly remove all old grease.
  8.  
  9. Covering the spindle with a clean cloth, brush all loose dirt and dust from the brake assembly. Remove the cloth carefully so as to not get dirt on the spindle.
  10.  
  11. If the inner and/or outer bearing cups were removed, install the replacement cups on the hub. Be sure that the cups seat properly in the hub.
  12.  
  13. It is imperative that all old grease be removed from the bearings and surrounding surfaces before repacking. The new lithium-based grease is not compatible with the sodium base grease used in the past.
  14.  
  15. Install the hub and disc on the wheel spindle. To prevent damage to the grease retainer and spindle threads, keep the hub centered on the spindle.
  16.  
  17. Install the outer bearing cone and roller assembly, along with the flat washer, on the spindle. Install the adjusting nut.
  18.  
  19. With the wheel rotating to seat the bearing, adjust the wheel bearings by torquing the adjusting nut to 30-40 ft. lbs. (41-54 Nm). Then back off the adjusting nut 1 / 2 turn. Retighten the adjusting nut finger-tight. Install the nut lock, aligning the castellations with the hole, then install a new cotter pin. Bend the ends of the cotter pin around the castellations (not over top) to prevent interference with the radio static collector in the grease cap. Install the grease cap.
  20.  
  21. Install the wheels.
  22.  
  23. Lower the vehicle, tighten lug nuts.
  24.  
  25. Install the wheel cover.
  26.  

4-Wheel Drive Dakota Models

See Figures 4, 5, 6, 7 and 8

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheel cover. Remove the wheel.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the front hub retaining hardware

  1. Remove the cotter pin, nut lock and spring washer.
  2.  
  3. Have an assistant apply the brakes. With a long breaker bar and the correct size socket, loosen the hub nut. Remove the nut and washer.
  4.  
  5. Remove the brake caliper guide pins and separate the caliper assembly from the brake disc. Support the caliper with a strong wire or rope. Do not hang the caliper by its hose.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the disc brake mounting to the hub assembly-4WD Dakota models

  1. Remove the brake disc.
  2.  
  3. Remove the six mounting screws from the inner CV-joint flange. Compress the CV-joint and move it away from the axle flange. Again, use a wire to support the CV-joint and axle shaft during service. Don't let the shaft hang by the CV-joint. Support the assembly at the CV-joint housings and separate from the hub by pulling on the outer CV-joint.
  4.  
  5. Remove the four hub and bearing assembly mounting screws from the rear of the steering knuckle.
  6.  



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Fig. Fig. 6: Exploded view of the front hub assembly

  1. Remove the hub and bearing assembly.
  2.  

To install:
  1. Remove and discard the old grease retainer. Install a new grease seal in the steering knuckle using tool No. C-4698 to press in the seal.
  2.  
  3. If the steering knuckle and driveshaft were separated, carefully clean the seal and wear sleeve and lubricate both components. Lubricate the full circumference of the seal and wear sleeve with multipurpose grease.
  4.  
  5. Install the halfshaft through the hub. Attach the inner CV-joint. Tighten the fasteners to 56 ft. lbs. (88 Nm).
  6.  



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Fig. Fig. 7: Make sure the washer, hub nut and shaft are clean and dry before installing

  1. Install the brake disc. Install the caliper. Tighten the guide pins to 22 ft. lbs. (30 Nm).
  2.  
  3. Install the washer and hub nut. Again have an assistant apply the brakes. Tighten the hub nut to 190 ft. lbs. (258 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Bend the cotter pin as shown to lock the nut assembly in place

  1. Install the spring washer, nut lock and a new cotter pin. Bend the cotter pin prongs around the nut lock,
  2.  
  3. Install the wheels. Tighten the lug nuts to 95 ft. lbs. (16 Nm).
  4.  
  5. Lower the vehicle. Install the wheel cover, if applicable.
  6.  

ADJUSTMENT
  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the grease cap and remove excess grease from the end of the spindle.
  4.  
  5. Remove the cotter pin and nut lock.
  6.  
  7. Loosen, but do not remove the hub nut.
  8.  
  9. Rotate the wheel, hub and disc assembly while tightening the adjusting nut to 30-40 ft. lbs. (41-54 Nm) in order to seat the bearings.
  10.  
  11. Back off the adjusting nut 1 / 2 , then retighten the adjusting nut finger-tight.
  12.  
  13. Locate the nut lock on the adjusting nut so that the castellations on the lock are aligned with the cotter pin hole in the spindle.
  14.  
  15. Install the new cotter pin, bending the ends of the cotter pin around the castellated flange of the nut lock.
  16.  
  17. Check the wheel for proper rotation, then install the grease cap filled with lubricant. If the wheel still does not rotate properly, inspect and clean or replace the wheel bearings and cups.
  18.  
  19. Install the wheels.
  20.  
  21. Lower the vehicle, tighten lug nuts.
  22.  
  23. Install the wheel cover.
  24.  

Model 44 Front Axle

See Figures 9, 10, 11 and 12

The Model 44 front axle is used for Ram Truck and Ramcharger vehicles equipped for standard duty 4WD operation.

  1. Raise all four wheels of the vehicle and install jackstands.
  2.  


CAUTION
Whenever servicing the front axle, all four wheels MUST be raised off the ground. Otherwise it is possible to cause the rear wheels to drive the vehicle off the jackstands causing severe injury or death.



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Fig. Fig. 9: Exploded view of the Model 44 front drive locking hub

  1. Refer to Front Drive Axle for removal of hub assemblies.
  2.  
  3. Remove the wheel bearing locknut, with a hub nut wrench.
  4.  



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Fig. Fig. 10: Use the correct socket to remove the wheel bearing nut lock

  1. Remove the lockring from the bearing adjusting nut. This can be done with your finger tips or a screwdriver.
  2.  
  3. Remove the bearing adjusting nut using hub wrench No. C-4170-A, or equivalent.
  4.  
  5. Remove and suspend the caliper out of the way.
  6.  



Click image to see an enlarged view

Fig. Fig. 11: Dana Model 44 wheel bearing adjusting nut, retaining washer and nut lock

  1. Slide the hub and disc assembly off of the spindle. Be careful, as the outer bearing will slide out as the hub is removed.
  2.  



Click image to see an enlarged view

Fig. Fig. 12: Cutaway view of the Model 44 hub and bearings

Inspection:
  1. Lay the hub on a clean work surface. Using a driver, carefully remove the inner bearing cone and seal from the hub.
  2.  
  3. Clean all surfaces with mineral spirits and dry thoroughly, preferably with compressed air, if available.
  4.  
  5. Inspect the bearing cups for pits or cracks. If necessary, remove them with a drift. If new cups are installed, install new bearings and repack with the specified grease.
  6.  

To install:
  1. Lubricate the bearings with wheel bearing grease. Clean all old grease from the hub. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages.
  2.  
  3. Drive new cups into place with a driver, making sure that they are fully seated.
  4.  
  5. Position the inner bearing cone and roller in the inner cup and install the grease retainer.
  6.  
  7. Carefully position the hub and disc assembly on the spindle.
  8.  
  9. Install the outer bearing cone and roller, along with the adjusting nut.
  10.  

The adjusting nut has a small dowel on one side. This dowel faces outward to engage the locking ring.

  1. Using hub wrench No. C-4170-A, or equivalent, tighten the bearing adjusting nut to 50 ft. lbs. (68 Nm), while rotating the wheel back and forth to seat the bearings.
  2.  
  3. Back off the adjusting nut approximately 90°.
  4.  
  5. Install the lockring by turning the nut to the nearest hole and inserting the dowel pin.
  6.  

The dowel pin must seat in a lockring hole for proper bearing adjustment and wheel retention.

  1. Install the outer locknut. Tighten to 50-80 ft. lbs. (67-3 Nm). Final end-play of the wheel on the spindle should be 0.001-0.010 in. (0.025-0.25mm).
  2.  
  3. Assemble the hub parts.
  4.  
  5. Install the caliper.
  6.  
  7. Remove the jackstands and lower the vehicle.
  8.  

Dualmatic Front Locking Hubs

See Figure 13

  1. Turn the knob to the ENGAGE position.
  2.  



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Fig. Fig. 13: Exploded view of the Dualmatic front locking hub

  1. Apply pressure to the face of the knob, then remove the three screws spaced 120° apart and nearest the flange.
  2.  
  3. Pull outward and remove the knob from the mounting base.
  4.  
  5. Remove the snapring from the axle shaft.
  6.  
  7. Separate and remove the locking hub assembly from the rotor hub. Discard the gasket.
  8.  

Inspection:
  1. Clean all parts in mineral spirits. If available, use compressed air to blow them dry.
  2.  
  3. Examine the splines, the shift knob, the cam, the sliding gear, the drive shaft gear, and the base for any damage or excessive wear. Replace any damaged parts.
  4.  

Assembly/Installation:
  1. Coat all parts with multi-purpose grease prior to assembly.
  2.  
  3. Place a new gasket and the locking hub on the rotor.
  4.  
  5. Install the capscrews and lockwasher, then tighten them to 30-40 ft. lbs. (41-54 Nm).
  6.  
  7. Install the snapring.
  8.  
  9. Position the shift knob on the mounting base. Align the splines by pushing inward and turning it clockwise to lock it in position.
  10.  
  11. Install and tighten the three screws.
  12.  

Automatic Locking Hubs

REMOVAL AND DISASSEMBLY

See Figures 14, 15, 16, 17, 18, 19 and 20

  1. Remove the five Torx® screws securing the hub cover.
  2.  
  3. Remove the cover.
  4.  
  5. Remove the bearing race spring assembly.
  6.  



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Fig. Fig. 14: Exploded view of the automatic front locking hubs

  1. Remove the sealing ring.
  2.  



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Fig. Fig. 15: Remove the wire retaining ring-automatic front locking hubs

  1. Remove the seal bridge retainer and bearing components.
  2.  
  3. Squeeze together the tangs of the wire retainer with needle-nosed pliers and pull the remaining components of the locking hub from the wheel.
  4.  



Click image to see an enlarged view

Fig. Fig. 16: Details of the automatic locking hub drag sleeve retainer washer

  1. If the hub was locked when removed, you must first unlock it:
    1. Hold the hub outer ring.
    2.  
    3. Rotate the drag sleeve in either direction.
    4.  

  2.  
  3. With the cover removed, turn the clutch gear until it drops, to engage the outer clutch housing.
  4.  
  5. Remove the retaining ring holding the drag sleeve to the hub sleeve.
  6.  



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Fig. Fig. 17: Remove the cover to the automatic locking hub

  1. Remove the spacer.
  2.  



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Fig. Fig. 18: Remove drag sleeve, detent and brake band assembly from the automatic locking hub

  1. Lift and tilt the drag sleeve and detent to free the brake band tangs from the rectangular opening in the inner cage.
  2.  



Click image to see an enlarged view

Fig. Fig. 19: Details of the automatic locking hub outer clutch housing including the plastic outer case

  1. Remove the drag sleeve and detent, along with the brake band assembly, or brake band retainer.
  2.  


WARNING
Never remove the brake band or band retainer from the drag sleeve and detent!

  1. Remove the retaining ring from the outer clutch housing groove.
  2.  



Click image to see an enlarged view

Fig. Fig. 20: Details of the automatic locking hub clutch gear and hub sleeve assembly

  1. Using a small prybar, carefully pry the plastic outer cage free from the inner cage, then remove the inner cage.
  2.  
  3. Pry free all five lugs and remove the plastic outer cage from the outer clutch housing.
  4.  
  5. Remove the clutch gear and hub sleeve assembly from the outer clutch housing.
  6.  
  7. Compress the clutch gear return spring and remove the retaining ring from the clutch gear hub sleeve.
  8.  


CAUTION
To prevent injury, use a spring compressor to hold the spring securely!

  1. Carefully release the spring tension, remove the spring support washer, return spring retainers and return spring from the hub sleeve.
  2.  
  3. Remove the C-ring from the hub sleeve.
  4.  
  5. Remove the clutch gear, spring and cam follower.
  6.  

INSPECTION
  1. Wash all parts in clean solvent.
  2.  
  3. Check all parts for wear or damage and replace any problem parts.
  4.  
  5. Examine the wire retaining ring for kinks, bends and diameter. Diameter range should be 0.088-0.094 in. (2.2-2.4mm).
  6.  

LUBRICATION

The hubs should be lubricated every 24,000 miles (38,600 km), or, after being run in deep water.

  1. All parts except the bearing and race, brake band and drag sleeve, should be dipped in clean ATF+3 prior to assembly.
  2.  
  3. Pack the bearing race with Mopar 4293040 lubricant, or equivalent.
  4.  
  5. Lubricate the brake band with 1.5 grams of the same lubricant.
  6.  


WARNING
The use of any other lubricant may cause hub failure!

ASSEMBLY AND INSTALLATION
  1. Snap the cam follower legs over the tooth gaps at the flat surfaces of the clutch gear.
  2.  

Do not pry the legs of the cam apart.

  1. Compress and slide the conical spring into position between the cam follower and the clutch gear with the large diameter of the spring contacting the face of the clutch gear.
  2.  
  3. Install the assembled cam follower, conical spring and clutch gear assembly onto the hub sleeve with the teeth of the cam follower near the step at the end of the hub sleeve.
  4.  
  5. Position the C-ring between the clutch gear and the cam follower, then, snap it into place in the groove of the hub sleeve.
  6.  
  7. Place a spring retainer at the end of the return spring, then position the spring and retainer over the clutch gear.
  8.  
  9. Install a spring retainer and the spring support washer on the remaining end of the return spring. Compress the return spring, install the retainer ring into the groove at the end of the hub sleeve. Clamp the spring securely!
  10.  
  11. Install the clutch gear and hub sleeve assembly into the outer clutch housing.
  12.  
  13. Install three of the clutch screws into the outer face of the clutch housing.
  14.  
  15. Position the plastic outer cage into the outer clutch housing, with the ramps of the plastic outer cage near the cam follower. Carefully work the outer cage into the outer clutch housing until the small external tabs of the plastic cage locate in the wide groove of the inner cage.
  16.  
  17. Install the steel inner cage into the outer cage, aligning the lug of the outer cage with the rectangular opening in the inner cage.
  18.  
  19. Install the retaining ring into the outer clutch housing groove to lock the outer cage in place.
  20.  
  21. Position one of the two brake band tangs on each side of the outer cage lug located at the rectangular opening of the steel inner cage. It may be necessary to tilt the drag sleeve while engaging the the brake band tangs. With the brake band tangs engaged, the drag sleeve teeth will be meshed with the teeth of the cam follower.
  22.  
  23. Remove the three recently installed screws from the clutch housing face.
  24.  
  25. Install the spacer and retaining ring to secure the drag sleeve in position.
  26.  
  27. Install the hub assembly on the axle.
  28.  
  29. Position the wire retaining ring in the groove machined in the outer clutch housing surface with the retaining ring tangs pointed away from the splines.
  30.  
  31. Hold the tangs together and assemble the seal bridge over the tangs, positioned in such a way that the bent-down tabs of the seal bridge clamp the wire tangs together.
  32.  
  33. Install the O-ring in the outer clutch housing groove and over the seal bridge.
  34.  
  35. Position the bearing over the inner race and lubricate it as described above. Install the bearing retaining clip in the inner race. The clip must be assembled on the bearing with the balls visible as shown in the accompanying illustration.
  36.  
  37. Install the bearing and retainer assembly into the end of the hub sleeve. Install the seal ring over the outer clutch housing.
  38.  
  39. Position the bearing race spring into the bore in the cover.
  40.  
  41. Install the spring and cover assembly, install the five screws and tighten them to 50 inch lbs. (6 Nm).
  42.  
  43. The hub should turn freely.
  44.  

 
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