DODGE RAM 2001 Service Repair Manual

Fig. 14 Gear Tooth Contact Patterns
3 - 88 REAR AXLE-91/4BR/BE
REAR AXLE - 9 1/4 (Continued)

and differential housing on opposite sides of the hub
(Fig. 15) .
(3) If side gear clearances is no more than 0.005
inch. Determine if the axle shaft is contacting the
pinion 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 shaft, the side
gear clearance is acceptable.
(4) If clearance is more than 0.005 inch (axle shaft
not contacting pinion shaft), record the side gear
clearance. Remove the thrust washer and measureits 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. 16). In some cases, the end of the axle
shaft will move and contact the pinion shaft when
the feeler gauge is inserted. The C-lock is preventing
the side gear from sliding on the axle shaft.
(5) If there is no side gear clearance, remove the
C-lock from the axle shaft. Use a micrometer to mea-
sure the thrust washer thickness. Record the thick-
ness and re-install the thrust washer. Assemble the
differential case without the C-lock installed and re-
measure the side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-lock was installed to
thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
Fig. 15 Side Gear Clearance
1 - FEELER GAUGE
2 - SIDE GEAR
Fig. 16 Side Gear Calculations
BR/BEREAR AXLE - 9 1/4 3 - 89
REAR AXLE - 9 1/4 (Continued)

SPECIFICATIONS
REAR AXLE-91/4
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.21, 3.55, 3.92
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Diameter 235 mm (9.25 in.)
Ring Gear Backlash 0.13-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 1.7-4 N´m (15-35 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 136 100 -
Ring Gear Bolts 157 115 -
Pinion Nut Minimum 285 210 -
Adjuster Lock Screw 11 8 96
Backing Plate Nuts 54 40 -
SPECIAL TOOLS
REAR AXLE-91/4
Puller 6790
Holder Yoke 6719A
Remover, Bearing 6310
Installer C-4198
3 - 90 REAR AXLE-91/4BR/BE
REAR AXLE - 9 1/4 (Continued)

Handle C-4171
InstallerÐC-4076-B
Handle C-4735-1
Remover C-4828
Puller C-452
Installer C-3860-A
Installer C-3718
Wrench C-4164
Puller/Press C-293-PA
BR/BEREAR AXLE - 9 1/4 3 - 91
REAR AXLE - 9 1/4 (Continued)

Adapters C-293-47
Plug C-293-3
Installer C-4213
Fixture 8136
Remover C-4309
Adapters C-293-37
Installer C-4310
Installer D-129
Installer C-3095
Trac-lok Tools C-4487
3 - 92 REAR AXLE-91/4BR/BE
REAR AXLE - 9 1/4 (Continued)

AXLE SHAFTS
REMOVAL
(1) Place the transmission in NEUTRAL and raise
and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL) ..
(4) Clean all foreign material from housing cover
area.
(5) Remove the housing cover and drain lubricant.
(6) Rotate differential case to access the pinion
shaft lock screw. Remove lock screw and pinion shaft
from differential case (Fig. 17).
(7) Push axle shaft inward then remove axle shaft
C-lock (Fig. 18).
(8) Remove axle shaft being carefull not to damage
shaft bearing and seal.
(9) Inspect axle shaft seal for leakage or damage.
(10) Inspect axle shaft bearing contact surface for
signs of brinelling, galling and pitting.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing and
engage it into side gear splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) Insert C-lock in end of axle shaft. Push axle
shaft outward to seat C-lock in side gear.
(3) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctiteton the
threads. Tighten lock screw to 11 N´m (8 ft. lbs.).
Trac-lok Tools 8139
Height Block 8542
Arbor Discs 8541
Fig. 17 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION MATE SHAFT
Fig. 18 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
BR/BEREAR AXLE - 9 1/4 3 - 93
REAR AXLE - 9 1/4 (Continued)

(5) Install cover and fill with gear lubricant.
(6)
Install brake drum (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - INSTALLATION).
(7) Install wheel and tire assemblies.
(8) Remove support and lower vehicle.
AXLE SHAFT SEALS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 19).
INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install anewaxle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(3) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(4) Install the axle shaft.
AXLE BEARINGS
REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 20).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.(3) Remove the axle shaft bearing from the axle
tube with Bearing Removal 6310 and Adapter 6310-9
(Fig. 21).
Fig. 19 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3-PRYBAR
Fig. 20 Axle Seal
1 - AXLE TUBE
2 - AXLE SEAL
3-PRYBAR
Fig. 21 Axle Shaft Bearing
1 - NUT
2 - GUIDE PLATE
3 - GUIDE
4 - THREADED ROD
5 - ADAPTER
6 - FOOT
7 - AXLE TUBE
3 - 94 REAR AXLE-91/4BR/BE
AXLE SHAFTS (Continued)

INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install the axle shaft bearing with Installer
C-4198 and Handle C-4171 . Ensure that the bearing
part number is against the installer. Verify that the
bearing in installed straight and the tool fully con-
tacts the axle tube when seating the bearing.
(3) Install anewaxle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, companion flange and
pinion shaft for installation reference.
(3) Remove the propeller shaft from the companion
flange. Secure the propeller shaft in an upright posi-
tion to prevent damage to the rear universal joint.
(4) Remove the wheel and tire assemblies.
(5) Remove the brake drums to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate the companion flange three or four
times.
(7) Measure the amount of torque necessary to
rotate the pinion with an inch pound torque wrench.
Record the torque reading for installation reference.
(8) Install socket head bolts into two of the
threaded holes in the companion flange, 180É apart.
(9) Position Holder 6719A against the companion
flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the
bolts so the holder is held to the flange.
(10) Hold the flange with holder and remove the
pinion nut and washer.
(11) Remove the companion flange with Remover
C-452 (Fig. 22).
(12) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
INSTALLATION
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with Installer C-3860-A
and Handle C-4171.NOTE: The seal is correctly installed when the seal
flange contacts the face of the differential housing.
(3) Position the companion flange on the end of the
shaft with the reference marks aligned.
(4) Install socket head bolts into two of the
threaded holes in the companion flange, 180É apart.
(5) Position Holder 6719A against the companion
flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the
bolts so the holder is held to the flange.
(6) Seat companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Remove the installer and install the pinion
washer and anewpinion nut. The convex side of the
washer must face outward.
CAUTION: Do not exceed the minimum tightening
torque when installing the companion flange retain-
ing nut at this point. Damage to collapsible spacer
or bearings may result.
(8) Hold companion flange with Holder 6719 and
tighten the pinion nut to 285 N´m (210 ft. lbs.) (Fig.
23). Rotate pinion several revolutions to ensure the
bearing rollers are seated.
(9) Rotate the pinion using an (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N´m (5 in. lbs.) (Fig. 24).
Fig. 22 Companion Flange Remover
1 - COMPANION FLANGE
2 - PULLER TOOL
BR/BEREAR AXLE - 9 1/4 3 - 95
AXLE BEARINGS (Continued)

CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.(10) If the rotating torque is low, use Holder 6719
to hold the companion flange (Fig. 23) and tighten
the pinion nut in 6.8 N´m (5 ft. lbs.) increments until
proper rotating torque is achieved.
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.
(11) The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N´m (210 ft.
lbs.).
(12) Install the propeller shaft with the installa-
tion reference marks aligned.
(13) Tighten the companion flange bolts to 108
N´m (80 ft. lbs.).
(14) Install the brake drums.
(15) Install wheel and tire assemblies and lower
the vehicle.
(16) Check the differential housing lubricant level.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential 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 the axle shafts.
(6) Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(7) Mark the differential housing and differential
bearing caps for installation reference (Fig. 25).
(8) Remove bearing threaded adjuster lock from
each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
(9) Loosen the threaded adjusters with Wrench
C-4164 (Fig. 26).
(10) Hold the differential case while removing
bearing caps and adjusters.
(11) Remove the differential case.
NOTE: Each differential bearing cup and threaded
adjuster must be kept with their respective bearing.
Fig. 23 Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 24 Pinion Rotation Torque
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
3 - 96 REAR AXLE-91/4BR/BE
PINION SEAL (Continued)

DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 27).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove the
differential pinions and thrust washers (Fig. 28).(4) Remove the differential side gears and thrust
washers.
Fig. 25 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARK
3 - BEARING CAPS
Fig. 26 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - TOOL C-4164
Fig. 27 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 28 Differential
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINIONS
BR/BEREAR AXLE - 9 1/4 3 - 97
DIFFERENTIAL (Continued)