DODGE RAM 2001 Service Repair Manual

ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion and thrust washers.
(3) Install the pinion shaft.
(4) Align the hole in the pinion shaft with the hole
in the differential case and install the pinion shaft
lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position. Carefully position the assem-
bled differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations
(Fig. 29).
(3) Install bearing cap bolts and tighten the upper
bolts to 14 N´m (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated.
(4) Perform the differential bearing preload and
adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tight-
ened to their final torque of 136 N´m (100 ft.lbs.)
before proceeding.
(5) Install the axle shafts.
(6) Apply a bead of Mopar Silicone Rubber Sealant
or equivalent to the housing cover (Fig. 30).Install the housing cover within 5 minutes
after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 N´m (30 ft. lbs.) torque.
(8) Fill differential with lubricant to bottom of the
fill plug hole. Refer to the Lubricant Specifications
for the quantity and type.
(9) Install the fill hole plug and lower the vehicle.
(10) Trac-lokydifferential equipped vehicles
should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
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.
Fig. 29 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - ADJUSTER LOCK
4 - BEARING CAP
Fig. 30 Differential Cover
1 - SEALANT
2 - DIFFERENTIAL COVER
3 - 98 REAR AXLE-91/4BR/BE
DIFFERENTIAL (Continued)

(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. 31).
(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
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 32).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-lokydifferential can be serviced
with the ring gear installed.
(3) Remove pinion shaft roll pin.
(4) Remove pinion shaft with a drift and hammer
(Fig. 33).
(5) Install and lubricate Step Plate C-6960-3 (Fig.
34).
(6) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
Fig. 31 Trac-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 32 Differential Case Holding Fixture
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 33 Pinion Shaft
1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR
BR/BEREAR AXLE - 9 1/4 3 - 99
DIFFERENTIAL - TRAC-LOK (Continued)

(7) Position a small screw driver in slot of
Threaded Adapter Disc C-6960-3 (Fig. 35) to prevent
adapter from turning.
(8) Install Forcing Screw C-6960-4 and tighten
screw to 122 N´m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 36).
(9) With a feeler gauge remove thrust washers
from behind the differential pinion gears (Fig. 37).
(10) Insert Turning Bar C-6960-2 into the pinion
shaft hole in the case (Fig. 38).
(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the dif-
ferential case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in correct order during
removal (Fig. 39).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in correct order during
removal.
Fig. 34 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATEFig. 35 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
Fig. 36 Compress Belleville Spring
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
3 - 100 REAR AXLE-91/4BR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

ASSEMBLY
Clean all components in cleaning solvent. Dry com-
ponents with compressed air. Inspect clutch pack
plates for wear, scoring or damage. Replace both
clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
Inspect differential case and pinion shaft. Replace if
worn or damaged.Lubricate each component with gear lubricant
before assembly.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 40).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(2) Position assembled clutch disc packs on the
side gear hubs.
(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 41).Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Position the differential case on the Holding
Fixture 6965.
(5) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 42).
(6) Install the upper side gear and clutch disc pack
(Fig. 42).
(7) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(8) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(9) Place differential pinion gears in position in
side gears and verify that the pinion shaft hole is
aligned.
Fig. 37 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 38 Pinion Gear
1 - PINION GEARS
2 - TOOL
Fig. 39 Side Gear & Clutch Pack
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
BR/BEREAR AXLE - 9 1/4 3 - 101
DIFFERENTIAL - TRAC-LOK (Continued)

(10) Rotate case with Turning Bar C-6960-2 until
the pinion shaft holes in pinion gears align with
holes in case. It may be necessary to slightly tighten
the forcing screw in order to install the pinion gears.
(11) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(12) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert pinion shaft into each pinion gear to
verify alignment.
(13) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(14) Install pinion shaft and align holes in shaft
and case.
(15) Install and seat pinion shaft roll pin in differ-
ential case. Peen the edge of the roll pin hole in the
case slightly in two places 180É apart.
(16) Lubricate all differential components with
hypoid gear lubricant.
Fig. 40 Clutch Disc Pack
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 41 Clutch Pack and Side Gear
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 42 Clutch Pack and Upper Side Gear
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE - C-6960-3
3 - 102 REAR AXLE-91/4BR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove bearings from the differential case
with Puller C-293-PA, Adapters C-293-47 and Plug
SP-293-3 (Fig. 43).
INSTALLATION
(1) Install differential side bearings with Installer
C-4213 and Handle C-4171 (Fig. 44).
(2) Install differential case in axle housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other.
(1) Raise and support vehicle.
(2) Remove wheel and tire assemblies.
(3) Mark companion flange and propeller shaft for
installation reference.
(4) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(5) Remove axle shafts.
(6) Remove differential from the differential hous-
ing.
(7) Place differential case in a vise with soft metal
jaw protectors. (Fig. 45).
(8) Remove ring gear bolts from the differential
case.
(9) Drive ring gear off the differential case with a
rawhide hammer (Fig. 45).
Fig. 43 Differential Bearing
1 - SPECIAL TOOL C-293±PA
2 - SPECIAL TOOL C-293±48
3 - BEARING
4 - DIFFERENTIAL
5 - SPECIAL TOOL SP-3289
Fig. 44 Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - BEARING INSTALLER
BR/BEREAR AXLE - 9 1/4 3 - 103

(10) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(11) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(12) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
(13) Remove the companion flange from the pinion
with Remover C-452 (Fig. 46).
(14) Remove the pinion from housing (Fig. 47).(15) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
(16) Remove oil slinger if equipped and front pin-
ion bearing.
(17) Remove front pinion bearing cup with
Remover C-4345 and Handle C±4171 (Fig. 48).
Fig. 45 Ring Gear
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 46 Companion Flange
1 - COMPANION FLANGE
2 - REMOVER
Fig. 47 Pinion Gear
1 - RAWHIDE HAMMER
Fig. 48 Front Pinion Bearing Cup
1 - REMOVER
2 - HANDLE
3 - 104 REAR AXLE-91/4BR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

(18) Remove the rear bearing cup from housing
(Fig. 49) with Remover C-4307 and Handle C±4171.
(19) Remove the collapsible preload spacer (Fig.
50).(20) Remove rear bearing from the pinion (Fig. 51)
with Puller/Press C-293-PA and Adapters C-293-47.
(21) Remove depth shims from the pinion shaft
and record shim thickness.
INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Do not replace the pinion without
replacing the ring gear. If ring and pinion gears or
bearings are replaced, Refer to Adjustments for Pin-
ion Gear Depth Setting.
(1) Apply Mopar Door Ease or stick lubricant to
outside surface of bearing cup.
(2) Install rear pinion bearing cup (Fig. 52) with
Installer C-4308 and Driver Handle C-4171 and ver-
ify cup is seated.
(3) Apply Mopar Door Ease or stick lubricant to
outside surface of bearing cup.
(4) Install front pinion bearing cup (Fig. 53) with
Installer D-130 and Handle C-4171 and verify cup is
seated.
(5) Install front pinion bearing.
(6) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer
C-4076±B and Handle C-4735-1 (Fig. 54).
(7) Place the proper thickness depth shim on the
pinion shaft.
Fig. 49 Rear Pinion Bearing Cup
1 - DRIVER
2 - HANDLE
Fig. 50 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARING
Fig. 51 Rear Pinion Bearing
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
BR/BEREAR AXLE - 9 1/4 3 - 105
PINION GEAR/RING GEAR/TONE RING (Continued)

(8) Install the rear bearing on the pinion (Fig. 55)
with Installer 6448 and a press.
Fig. 52 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 53 Front Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 54 Pinion Seal
1 - HANDLE
2 - DIFFERENTIAL HOUSING
3 - INSTALLER
Fig. 55 Rear Pinion Bearing
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
3 - 106 REAR AXLE-91/4BR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

(9) Install anewcollapsible preload spacer on pin-
ion shaft and install the pinion into the housing (Fig.
56).
(10) Install companion flange with Installer
C-3718 and Holder 6719.
(11) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(12) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(13) Install the companion flange washer and a
new nut on the pinion and tighten the pinion nut
until there is zero bearing end-play.
(14) Tighten the nut to 285 N´m (210 ft. lbs.) (Fig.
57).CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed.
(15) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until the desired rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 58).
(16) Check bearing rotating torque with an inch
pound torque wrench (Fig. 58). The torque necessary
to rotate the pinion should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2 to 5 N´m (15 to 35 in. lbs.).
(17) Position exciter ring on differential case.
(18) Using a brass drift, slowly and evenly tap the
exciter ring into position.
Fig. 56 Collapsible Preload Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - DEPTH SHIM
5 - REAR BEARINGFig. 57 Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - HOLDER
3 - TORQUE WRENCH
BR/BEREAR AXLE - 9 1/4 3 - 107
PINION GEAR/RING GEAR/TONE RING (Continued)