Might be a few months old this thread, but I am listing parts, etc right now to rebuild the front of my truck (118K on all original everything and it's really, really beat).
I've got everything listed I want to get, but similar to this thread I am struggling with u-joints.
If it matters, or helps, here's what I've found out based on quite a few hours of internet searching and reading and phone calls to various parts places, drive shaft specialists, etc (i.e. a lot of aggravation for freakin u-joints).
Truck: 2004 QC 4x4 Diesel Auto
Front drive axle u-joints: These are odd size AAM units. They will be listed as "AAM series 1485WJ". Spicer does not make a 1485 series, only 1480 series and these will NOT fit. However, Spicer does have the 5006813 which is made specifically for the AAM front axles. They are NOT greasable, however, as mentioned they are sealed very well and should last better than the crappy AAM parts. Spicer does NOT make a greasable unit for this application as of this post.
NEAPCO also makes joints for these axles. Part #3-0485
Front drive shaft: Strangely, the front drive shaft does apparently use standard Spicer sized u-joints (from everything I can find and have been told. I am not 100% sure of this yet!). The front shaft also uses a Constant Velocity "Double Cardan" joint. Most 2003-2005 trucks use the smaller 1330 size joints. There are some trucks made during this time frame that have the larger 1350 (AAM 1355) size joints. You need to measure the cap diameter on your joints to determine which you have. 1330 series = 1 and 1/16" diameter and the 1350/55 = 1 and 3/16".
You will need 3 u-joints for the front drive shaft. 2 for the CV joint center yoke and 1 for the differential end of the drive shaft.
You have your choice of the Spicer 1330 or 1350 series to use for the double cardan joint and an SPL25 for the differential end (assuming what I have found out so far is true about the front drive shaft using Spicer sized joints, still working on that).
Rear drive shaft: The rear drive shaft gets ugly again. For whatever reason, AAM decided to use odd-sized u-joints. The cap diameters are pretty standard, spicer makes joints that will meet this spec, but the issue is the lockup dimension (distance from the end of one cap to the end of the other directly across the joint). AAM joints are .010" shorter.
RAMs with 6-speed trannies and 3-piece rear shafts use the AAM 1485 series joints. The Spicer 5006813 will NOT fit this application as the lockup dimension is way too short (For the AAM series 1485WJ series, the WJ stands for "Wheel Joint" and is nowhere near the same as joints on the rear drive shaft.). Most of the other trucks use the AAM 1415 series joints. Spicer does NOT make a joint that fits this application as of this posting.
I've read of some folks grinding the ends of the caps .005" on Spicer joints, or having the clips thinned by the same amount, but if this isn't done precisely, it throws the joint out of alignment. Some folks have managed to force Spicer units into the yolks, but this makes them too tight and causes heat and premature failure.
Again, as of this posting, as far as I know, Spicer does NOT make a joint for the rear drive shafts on these trucks. However, one website I visited,
8LUG Truck Gear lists the Spicer 5-801X as "specifically designed for the one-piece rear drive shaft that utilize the 1410 series yokes" in the 03-up dodge trucks. I am trying to verify this claim as general searching on the 5-801X everywhere else does NOT make this claim. Again, this seems odd Spicer doesn't make AAM spec joints other than the front drive axles. Maybe we need to write Spicer and ask them to make them!
If anyone has information that updates, refutes, etc anything above, PLEASE post!
Since I am on this roll, let me also delve into the ball joints and wheel bearings. If the odd-sized u-joints aren't enough of a PIA, just wait till you dig into the ball joints and bearings!
The more I read about these AAM 9.25" axles, the madder I get. It seems it was an extremely poor choice on Dodge's part to use these infernal things. I can't understand why Dodge went to AAM instead of keeping the Danas. Bottom line, the AAM 9.25" axle on the front of these trucks is complete junk. So much so that I am seriously considering and researching what it would take to swap it out for a Dana set up.
Problem #1: The wheel bearings are not serviceable. You have to replace the entire hub and bearing assembly. Ok, on the surface this doesn't sound too terrible until you find out one freakin hub/bearing assembly is expensive as hell. I see prices running between $300-$400...EACH! 'nuff said on that.
Problem #2: The ball joints are an incredibly poor design/set up. Unfortunately, even a full set of Carli or other expensive "super" ball joints may not cure the problem much longer than stock ball joints.
The issue is that the setup on the AAM axle does not place the upper and lower ball joints in any kind of alignment with each other. The upper ball joints are NOT weight bearing at all and are free-floating in the vertical to allow for the different ball arcs when steering. The entire weight of the front end of your RAM rides on the lower ball joints! If that's bad enough, the lower ball joints are only 4% bigger than the ball joints used on much lighter vehicles, like Jeeps CJs and even on those vehicles, all 4 ball joints are weight bearing. The RAM ball joints have no provision for any kind of pre-load setting to keep things tight and smooth. ANY wear on the lower ball joints instantly manifests itself as looseness. In fact, the 2003 Service Manual gives NO specification for acceptable movement or play! Later manuals quote up to .09" vertical and .06" horizontal play as still in spec!!!
This enough to almost convince me to save the $800 for the monster Carli joints and just slap stock crap back in it because replacing the ball joints is an every 2-3 year deal apparently.
Again, I hope this is helpful.