DODGE RAM 2001 Service Repair Manual

(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.
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.
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 - 128 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL (Continued)

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.
(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.
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 - 248RBI 3 - 129
DIFFERENTIAL (Continued)

(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.
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. Thiswill 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
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 36).
(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. 37).
(5) Install and lubricate Step Plate C-6960-3 (Fig.
38).
Fig. 34 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 35 Trac-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 130 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL (Continued)

(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.
(7) Position a small screw driver in slot of
Threaded Adapter Disc C-6960-3 (Fig. 39) to prevent
adapter from turning.
Fig. 36 Differential Case Holding Fixture
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 37 Pinion Shaft
1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR
Fig. 38 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
Fig. 39 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
BR/BEREAR AXLE - 248RBI 3 - 131
DIFFERENTIAL - TRAC-LOK (Continued)

(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. 40).
(9) With a feeler gauge remove thrust washers
from behind the differential pinion gears (Fig. 41).
(10) Insert Turning Bar C-6960-2 into the pinion
shaft hole in the case (Fig. 42).(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. 43).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in correct order during
removal.
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. 44).
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.
Fig. 40 Compress Belleville Spring
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
Fig. 41 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 42 Pinion Gear
1 - PINION GEARS
2 - TOOL
3 - 132 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

(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. 45).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. 46).
(6) Install the upper side gear and clutch disc pack
(Fig. 46).
(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.
(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.
Fig. 43 Side Gear & Clutch Pack
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 44 Clutch Disc Pack
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 45 Clutch Pack and Side Gear
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH DISC PACK
BR/BEREAR AXLE - 248RBI 3 - 133
DIFFERENTIAL - TRAC-LOK (Continued)

(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.
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. 47).
INSTALLATION
(1) Using tool C-4190 with handle C-4171, install
differential side bearings (Fig. 48).
(2) Install differential case in axle housing.
Fig. 46 Clutch Pack and Upper Side Gear
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE - C-6960-3
Fig. 47 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 - 134 REAR AXLE - 248RBIBR/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 pinion gear.
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 49)
(3) Remove bolts holding ring gear to differential
case.
(4) Using a soft hammer, drive ring gear from dif-
ferential case (Fig. 49).
(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.
Using suitable wire, tie propeller shaft to underbody.
(8) Using Yoke Holder 6719 to hold yoke, remove
the pinion yoke nut and washer.
(9) Using Remover C±452 and Wrench C±3281,
remove the pinion yoke from pinion shaft (Fig. 50).(10) Remove the pinion gear from housing (Fig.
51). Catch the pinion with your hand to prevent it
from falling and being damaged.
(11) Remove the pinion seal with a slide hammer
or suitable pry bar.
(12) Remove oil slinger, if equipped, and the front
pinion bearing.
(13) Remove the front pinion bearing cup with
Remover D-158 and Handle C±4171 (Fig. 52).
(14) Remove the rear bearing cup from housing
(Fig. 53). Use Remover D-162 and Handle C±4171.
(15) Remove the collapsible preload spacer (Fig.
54)from pinion gears.
Fig. 48 Install Differential Side Bearings
1 - HANDLE C-4171
2 - DIFFERENTIAL CASE
3 - BEARING
4 - TOOL C-4190
Fig. 49 Ring Gear Removal
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 50 Pinion Yoke Removal
1 - SPECIAL TOOL C-3281
2 - YOKE
3 - SPECIAL TOOL C-452
BR/BEREAR AXLE - 248RBI 3 - 135
DIFFERENTIAL CASE BEARINGS (Continued)

Fig. 51 Remove Pinion Gear
1 - RAWHIDE HAMMER
Fig. 52 Front Bearing Cup Removal
1 - REMOVER
2 - HANDLE
Fig. 53 Rear Bearing Cup Removal
1 - DRIVER
2 - HANDLE
Fig. 54 Collapsible Spacer
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
3 - 136 REAR AXLE - 248RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

(16) Remove the rear bearing from the pinion with
Puller/Press C±293-PA and Adapters C±293±37 (Fig.
55).
Place 4 adapter blocks so they do not damage
the bearing cage.
(17) Remove the pinion depth shims from the pin-
ion gear shaft. Record the total thickness of the
depth shims.
INSTALLATION
(1) Apply MopartDoor Ease stick lubricant to out-
side surface of bearing cup. Install the pinion rear
bearing cup with Installer D-111 and Handle C-4171
(Fig. 56). Ensure cup is correctly seated.
(2) Apply MopartDoor Ease stick lubricant to out-
side surface of bearing cup. Install the pinion front
bearing cup with Installer D-146 and Handle C-4171
(Fig. 57).
(3) Install pinion front bearing and oil slinger, if
equipped. Apply a light coating of gear lubricant on
the lip of pinion seal.
Fig. 55 Inner Bearing Removal
1 - SPECIAL TOOL C-293±PA
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
Fig. 56 Pinion Rear Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 57 Pinion Front Bearing Cup
1 - INSTALLER
2 - HANDLE
BR/BEREAR AXLE - 248RBI 3 - 137
PINION GEAR/RING GEAR/TONE RING (Continued)