differential DODGE RAM 2001 Service Repair Manual

NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(10) Install the propeller shaft with the installa-
tion reference marks aligned.
(11) Tighten the universal joint yoke clamp screws
to 19 N´m (14 ft. lbs.).
(12) Install the brake drums.
(13) Add gear lubricant to the differential housing,
if necessary. Refer to the Lubricant Specifications for
gear lubricant requirements.
(14) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
(3) Remove differential housing cover and drain
the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove axle shafts.
(6) Note the orientation of the installation refer-
ence letters stamped on the bearing caps and hous-
ing machined sealing surface (Fig. 26).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 27).(9) Install the hold down clamps and tighten the
tool turnbuckle finger-tight.
(10) Install a Pilot Stud C-3288-B at the left side
of the differential housing. Attach dial indicator to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing (Fig. 27) and
zero the indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 27).
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(12) Remove the dial indicator.
(13) Pry the differential case loose from the hous-
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 28).
(14) Remove the case from housing. Tag bearing
cups to indicate their location.
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.Fig. 26 Bearing Cap Identification
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 27 Spread Differential Housing
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
3 - 158 REAR AXLE - 267RBIBR/BE
PINION SEAL (Continued)

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.
(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.
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
BR/BEREAR AXLE - 267RBI 3 - 159
DIFFERENTIAL (Continued)

(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.).
(14) Remove support and lower vehicle.
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
3 - 160 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL (Continued)

DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING - POWR-LOKY
TEST
WARNING: WHEN SERVICING VEHICLES WITH A
POWER-LOKYDIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A POWER-LOKYAXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
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 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 Powr-Lokydifferential has a two-piece cross
shaft and uses 2 disc and 3 plates for each clutch
pack. One plate and one disc in each clutch pack is
dished.
NOTE: Pay close attention to the clutch pack
arrangement during this procedure. Note the direc-
tion of the concave and convex side of the plates
and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 36).
(2) Remove the case attaching bolts and remove
the button cover half (Fig. 37).
(3) Remove top clutch pack (Fig. 38).
(4) Remove top side gear clutch ring.
(5) Remove top side gear.
(6) Remove pinion mate gears and cross shafts.
(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 correct installation in
their original positions.
Fig. 34 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 35 Powr-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
BR/BEREAR AXLE - 267RBI 3 - 161
DIFFERENTIAL (Continued)

Fig. 37 Cover Half Removal
1 - CLUTCH PLATES
2 - BUTTON HALF
3 - FLANGE HALFFig. 36 Case Marked
1 - REFERENCE MARKS
Fig. 38 Powr-LokYComponents
1 - FLANGE HALF
2 - CLUTCH RING
3 - SIDE GEAR
4 - PINION MATE GEAR
5 - SCREW
6 - BUTTON HALF7 - PINION MATE CROSS SHAFT
8 - DISHED DISC
9 - PLATE
10 - DISHED DISC
11 - PLATE
3 - 162 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL - POWR-LOK (Continued)

ASSEMBLY
The Powr-Lokydifferential has a two-piece cross
shaft and uses 2 disc and 3 plates for each clutch
pack. One plate and one disc in each clutch pack is
dished.
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
(1) Saturate the clutch plates with MopartHypoid
Gear Lubricant or Additive (Fig. 39). Assemble clutch
packs into the side gear plate in exactly the same
position as removed (Fig. 38).
(2) Line up the plate ears and install the assem-
bled pack into the flange half (Fig. 40). Ensure that
the clutch plate lugs enter the slots in the case. Also
ensure that the clutch pack bottoms out on the case.
(3) Install pinion mate shafts and pinion mate
gears (Fig. 41).Make sure shafts are correctly
installed according to the alignment marks.
(4) Lubricate and install the other side gear and
clutch pack (Fig. 40).
(5) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(6) Tighten body screws alternately and evenly.
Tighten screws to 89-94 N´m (65-70 ft. lbs.) torque
(Fig. 42).
Fig. 39 Clutch Pack Pre-lubrication
1 - CLUTCH PLATES
2 - SIDE GEAR
3 - CLUTCH RING
Fig. 40 Clutch Pack Installation
1 - LUGS
2 - FLANGE HALF
3 - SIDE GEAR
Fig. 41 Clutch Pack
1 - CLUTCH PACK
2 - SIDE GEAR
3 - PINION GEARS AND MATE SHAFT
4 - ALIGNMENT MARKS
BR/BEREAR AXLE - 267RBI 3 - 163
DIFFERENTIAL - POWR-LOK (Continued)

If bolt heads have 7 radial lines or the number 180
stamped on the head, tighten these bolts to 122-136
N´m (90-100 ft. lbs.) torque.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-62 and
Step Plate 8139-2 (Fig. 43).
INSTALLATION
(1) Using tool C-4190 with handle C-4171, install
differential side bearings (Fig. 44).
(2) Install differential case in axle housing.
Fig. 42 Case Half Installation
1 - FIXTURE
2 - CASE BOLTS
3 - TORQUE WRENCHFig. 43 Differential Bearing
1 - SPECIAL TOOL C-293-PA
2 - SPECIAL TOOL C-293-62
3 - SPECIAL TOOL C-4487-1
4 - BEARING
5 - DIFFERENTIAL
3 - 164 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL - POWR-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. 45)
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 45).
(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. 46).
(10) Remove pinion gear from housing (Fig. 47).(11) Remove pinion seal with a slide hammer or
pry bar.
(12) Remove oil slinger, if equipped, and the front
pinion bearing.
(13) Remove front pinion bearing cup with
Remover D-158 and Handle C±4171 (Fig. 48).
(14) Remove rear bearing cup with Remover D-162
and Handle C-4171 (Fig. 49).
(15) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters C-293-37 (Fig.
50).
Place 4 adapter blocks so they do not damage
the bearing cage.
Fig. 44 Install Differential Side Bearings
1 - HANDLE C-4171
2 - DIFFERENTIAL CASE
3 - BEARING
4 - TOOL C-4190
Fig. 45 Ring Gear Removal
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 46 Pinion Yoke Removal
1 - WRENCH
2 - YOKE
3 - REMOVER
BR/BEREAR AXLE - 267RBI 3 - 165
DIFFERENTIAL CASE BEARINGS (Continued)

(7) Install original solid shims on pinion gears.
(8) Install yoke with Installer C-3718 and Yoke
Holder 6719 (Fig. 55).
(9) Install the yoke washer andnewnut on the
pinion gear. Tighten the nut to 298-380 N´m (220-280
ft. lbs.).
(10) Check bearing rotating torque with an inch
pound torque wrench (Fig. 56). Pinion rotating torque
should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2.3 to 5.1 N´m (20 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.
(16) Invert the differential case in the vise.
(17) Install new ring gear bolts and alternately
tighten to 176 N´m (130 ft. lbs.) (Fig. 57).
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 Yoke
1 - INSTALLER
2 - HOLDER
Fig. 56 Pinion Gear Rotation Torque
1 - PINION YOKE
2 - TORQUE WRENCH
Fig. 57 Ring Gear Bolt
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 168 REAR AXLE - 267RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 286RBI
TABLE OF CONTENTS
page page
REAR AXLE - 286RBI
DESCRIPTION..........................169
OPERATION............................169
DIAGNOSIS AND TESTING................171
AXLE...............................171
REMOVAL.............................173
INSTALLATION..........................174
ADJUSTMENTS.........................174
SPECIFICATIONS........................182
SPECIAL TOOLS........................182
AXLE SHAFTS
REMOVAL.............................185
INSTALLATION..........................185
AXLE BEARINGS
REMOVAL.............................185
INSTALLATION..........................185
PINION SEAL
REMOVAL.............................185INSTALLATION..........................185
DIFFERENTIAL
REMOVAL.............................187
DISASSEMBLY..........................188
ASSEMBLY............................188
INSTALLATION..........................188
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING................190
TRAC-LOK...........................190
DISASSEMBLY..........................190
ASSEMBLY............................190
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................192
INSTALLATION..........................192
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................193
INSTALLATION..........................195
REAR AXLE - 286RBI
DESCRIPTION
The 286 Rear Beam-design Iron (RBI) axle hous-
ings consist of an iron center casting (differential
housing) with axle shaft tubes extending from either
side. The tubes are pressed in to form a one-piece
axle housing.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axles are equipped with full-floating axle
shafts, meaning that loads are supported by the axle
housing tubes. The full-float axle shafts are retained
by bolts attached to the hub. The hub rides on two
bearings at the outboard end of the axle tube. The
axle shafts can be removed without disturbing or
removing the wheel bearings. The wheel bearings are
opposed tapered roller bearings and are contained in
the hub assembly.
The removable, stamped steel cover provides a
means for inspection and service without removing
the complete axle from the vehicle. A small, stamped
metal axle gear ratio identification tag is attached to
the housing cover via one of the cover bolts. This tag
also identifies the number of ring and pinion teeth.
The rear wheel anti-lock (RWAL) brake speed sen-
sor is attached to the top, forward exterior of the dif-
ferential housing. A seal is located between thesensor 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-fit-
ted onto the differential case against the ring gear
flange.
The differential case for the standard differential is
a one-piece design. The differential pinion mate shaft
is retained with a roll pin. Differential bearing pre-
load and ring gear backlash are adjusted by the use
of shims located between the differential bearing
cones and case. Pinion bearing preload is set and
maintained by the use of solid shims.
Axles equipped with a Trac-Lokydifferential are
optional for the 286 RBI axle. A Trac-lokydifferen-
tial contains two clutch packs, four pinion gears, and
a one-piece pinion mate cross shaft to provide
increased torque to the non-slipping wheel in addi-
tion to the standard differential components. A Trac-
lokydifferential for the 286 RBI axle has a two-piece
differential case.
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
BR/BEREAR AXLE - 286RBI 3 - 169