DODGE RAM 2001 Service Repair Manual

DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 29).
(3) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 30).(4) Remove the differential side gears and thrust
washers.
ASSEMBLY
(1) Install the differential side gears and thrust
washers.
(2) Install the pinion mate gears and thrust wash-
ers.
(3) Install the pinion gear mate shaft.
(4) Align the hole in the pinion gear mate shaft
with the hole in the differential case.
(5) Install and seat the pinion mate shaft roll-pin
in the differential case and mate shaft with a punch
and hammer (Fig. 31). Peen the edge of the roll-pin
hole in the differential case slightly in two places,
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) procedures to determine proper shim
selection.
Fig. 28 Differential Removal
1 - DIFFERENTIAL
2-PRYBAR
Fig. 29 Pinion Mate Shaft
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
Fig. 30 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
3 - 188 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL (Continued)

(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes. Install the hold
down clamps and tighten the tool turnbuckle finger-
tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the dial indica-
tor.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove the dial indicator.
(5) Install differential into the housing. Tap the
differential case with a rawhide/rubber hammer to
ensure the bearings are seated in housing (Fig. 32).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 33) and tighten bearing cap bolts to 109 N´m
(80 ft. lbs.).
(8) Install axle shafts.
(9) Install the hub bearings.
(10) Apply a bead of Mopar Silicone Rubber Seal-
ant or equivalent to the housing cover (Fig. 34).Install the housing cover within 5 minutes
after applying the sealant.
(11) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 47
N´m (35 ft. lbs.).
(12) Refill the differential with Mopar Hypoid
Gear Lubricant or equivalent to bottom of the fill
plug hole. Refer to the Lubricant Specifications for
correct quantity and type.
(13) Install the fill hole plug and tighten to 34 N´m
(25 ft. lbs.).
Fig. 31 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 32 Differential Case
1 - RAWHIDE HAMMER
Fig. 33 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
BR/BEREAR AXLE - 286RBI 3 - 189
DIFFERENTIAL (Continued)

(14) Remove support and lower vehicle.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKY
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lokyunit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-loky
Lubricant (friction modifier) should be added after
repair service or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 35).
(6) If rotating torque is less than 22 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
The Trac-Lokydifferential on this axle has a one-
piece cross shaft and uses one dished disc, regular 5
disc and 7 plates.
NOTE: Pay attention to the clutch pack arrangement
during disassembly. Note the direction of the con-
cave and convex side of the plates and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 36).
(2) Remove case attaching bolts and remove the
button cover half (Fig. 37).
(3) Remove top clutch pack.
(4) Remove top side gear clutch ring.
(5) Remove top side gear.
(6) Remove pinion mate gears and cross shaft.
(7) Remove the same parts listed above from the
ring gear flange half of the case. Keep these parts
with the flange cover half for installation in their
original positions.
ASSEMBLY
The Trac-Lokydifferential for this axle has a one-
piece cross shaft and uses one dished disc, 5 regular
disc and 7 plates for each clutch pack.
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Fig. 34 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 35 Trac-lokYTest - Typical
3 - 190 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL (Continued)

Lubricate each component with gear lube before
assembly and installation.(1) Saturate the clutch plates with Mopar Hypoid
Gear Lubricant or Additive.
(2) Assembly the discs and plates on the side gear
(Fig. 38) in the following order.
(a) Install dished disc on side gear.
(b) Install one disc on side gear.
(c) Install one plate on side gear.
(d) Install one disc on side gear.
(e) Install one plate on side gear.
(f) Install three discs on side gear.
(g) Install five plates on side gear.
(3) Line up the plate ears and install the assem-
bled pack into the flange half (Fig. 39). Verify clutch
plate lugs enter the slots in the case and clutch pack
bottoms out in the case.
(4) Install pinion mate shafts and pinion mate
gears (Fig. 40).Verify shafts are correctly
installed according to the alignment marks.
(5) Lubricate and install the other side gear and
clutch pack (Fig. 39).
(6) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(7) Tighten body screws alternately and evenly.
Tighten screws to 122-136 N´m (90-100 ft. lbs.) (Fig.
41).
Fig. 36 Case Marked
1 - REFERENCE MARKS
Fig. 37 Cover Half Removal
1 - CLUTCH PLATES
2 - BUTTON HALF
3 - FLANGE HALF
Fig. 38 Clutch Pack Assembly
1 - CLUTCH PLATES
2 - SIDE GEAR
3 - CLUTCH RING
BR/BEREAR AXLE - 286RBI 3 - 191
DIFFERENTIAL - TRAC-LOK (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove the bearings from the differential case
with Press 938 and Bearing Splitter 1130 (Fig. 42).
INSTALLATION
If ring and pinion gears have been replaced, verify
differential side bearing preload and gear mesh back-
lash.
(1) Using tool C-4190 with handle C-4171, install
differential side bearings (Fig. 43).
(2) Install differential in axle housing.
Fig. 39 Clutch Pack
1 - LUGS
2 - FLANGE HALF
3 - SIDE GEAR
Fig. 40 Clutch Pack
1 - CLUTCH PACK
2 - SIDE GEAR
3 - PINION GEARS AND MATE SHAFT
4 - ALIGNMENT MARKS
Fig. 41 Case Halfs
1 - FIXTURE
2 - CASE BOLTS
3 - TORQUE WRENCH
3 - 192 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the matched pinion gear.
(1) Remove differential from axle housing.
(2) Place differential case in a vise with soft metal
jaw protectors. (Fig. 44)
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 44).
(5) Use a brass drift and slowly tap the exciter
ring from the differential case.
(6) Mark pinion yoke and propeller shaft for
installation alignment.
(7) Disconnect propeller shaft from pinion yoke.
Tie propeller shaft to underbody.
(8) Using Yoke Holder 6719 to hold yoke, remove
pinion yoke nut and washer.
(9) Remove pinion yoke from pinion with Remover
C-452 and Wrench C-3281, shaft (Fig. 45).
(10) Remove pinion gear from housing (Fig. 46).
(11) Remove pinion seal with a slide hammer or
pry bar.
(12) Remove oil slinger, if equipped, and the front
pinion bearing.
Fig. 42 Differential Bearing Removal
1 - BRIDGE 938
2 - TOOL 1130
3 - DIFFERENTIAL
Fig. 43 Install Differential Side Bearings
1 - HANDLE C-4171
2 - DIFFERENTIAL CASE
3 - BEARING
4 - TOOL C-4190
Fig. 44 Ring Gear Removal
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
BR/BEREAR AXLE - 286RBI 3 - 193
DIFFERENTIAL CASE BEARINGS (Continued)

(13) Remove front pinion bearing cup with
Remover C-4307 and Handle C±4171 (Fig. 47).
(14) Remove rear bearing cup with Remover D-159
and Handle C-4171 (Fig. 48).
(15) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters DD-914-95 (Fig.
49).
Place 4 adapter blocks so they do not damage
the bearing cage.(16) Remove the pinion depth shims from the pin-
ion gear shaft. Record the total thickness of the
depth shims.
Fig. 45 Pinion Yoke Removal
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 46 Remove Pinion Gear
1 - RAWHIDE HAMMER
Fig. 47 Front Bearing Cup Removal
1 - REMOVER
2 - HANDLE
Fig. 48 Rear Bearing Cup Removal
1 - REMOVER
2 - HANDLE
3 - 194 REAR AXLE - 286RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

INSTALLATION
(1) Apply Mopar Door Ease stick lubricant to out-
side surface of bearing cup. Install the pinion rear
bearing cup with Installer C-4204 and Handle
C-4171 (Fig. 50) and verify cup is seated.
(2) Apply Mopar Door Ease stick lubricant to out-
side surface of bearing cup. Install the pinion front
bearing cup with Installer C-4308 and Handle
C-4171 (Fig. 51) and verify cup is seated.
(3) Install pinion front bearing and oil slinger, if
equipped. Apply a light coating of gear lubricant on
the lip of pinion seal.
(4) Install new pinion seal with an appropriate
installer 8108 (Fig. 52).
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If ring and pinion
gears are reused, the pinion depth shim should not
require replacement or adjustment. If the ring and
pinion gears are replaced refer to Adjustments to
select the proper thickness shim.(5) Place the proper thickness pinion depth shim
on the pinion gear.
Fig. 49 Rear Pinion Bearing Removal
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKSFig. 50 Pinion Rear Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 51 Pinion Front Bearing Cup
1 - INSTALLER
2 - HANDLE
BR/BEREAR AXLE - 286RBI 3 - 195
PINION GEAR/RING GEAR/TONE RING (Continued)

(6) Install rear bearing and oil slinger, if equipped,
on the pinion gear with Installer D-389 and a press
(Fig. 53).(7) Install original solid shims on pinion gears.
(8) Install yoke with Installer C-3718 and Yoke
Holder 6719 (Fig. 54).
(9) Install the yoke washer andnewnut on the
pinion gear. Tighten the nut to 637 N´m (470 ft. lbs.).
(10) Check bearing rotating torque with an inch
pound torque wrench (Fig. 55). Pinion rotating torque
should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2.8 to 5.1 N´m (25 to 45 in. lbs.).
(11) If rotating torque is less than the desired
rotating torque, remove the pinion yoke and decrease
the thickness of the solid shim pack if greater
increase shim pack. Changing the shim pack thick-
ness by 0.025 mm (0.001 in.) will change the rotating
torque approximately 0.9 N´m (8 in. lbs.).
(12) Invert the differential case.
(13) Position exciter ring on differential case.
(14) Using a brass drift, slowly and evenly tap the
exciter ring into position.
(15) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
Fig. 52 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 53 Rear Pinion Bearing
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
Fig. 54 Pinion Yoke
1 - INSTALLER
2 - HOLDER
3 - 196 REAR AXLE - 286RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

(16) Invert the differential case in the vise.
(17) Install new ring gear bolts and alternately
tighten to 298 N´m (220 ft. lbs.) (Fig. 56).
CAUTION: Do not reuse ring gear bolts, the bolts
can fracture causing extensive damage.(18) Install differential in housing and verify gear
mesh and contact pattern.
(19) Install propeller shaft with reference marks
aligned.
Fig. 55 Pinion Gear Rotation Torque
1 - PINION YOKE
2 - TORQUE WRENCH
Fig. 56 Ring Gear Bolt
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
BR/BEREAR AXLE - 286RBI 3 - 197
PINION GEAR/RING GEAR/TONE RING (Continued)