light DODGE RAM 2001 Service Owner's Guide

(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)

of traction, the wheel with the least traction may
spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
BR/BEREAR AXLE - 248RBI 3 - 111
REAR AXLE - 248RBI (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube.
INSTALLATION
(1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube.
(2) Install the bolts and tighten to 129 N´m (95 ft.
lbs.).
AXLE BEARINGS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake drum.
(3) Remove the axle shaft.
(4) Remove the lock wedge and adjustment nut.
Use Socket DD-1241±JD to remove the adjustment
nut.
(5) Remove the hub assembly. The outer axle bear-
ing will slide out as the hub is being removed.
(6) Remove inner grease seal and discard. Use
Installer 5064 and Handle C-4171 to drive grease
seal and inner axle bearing from the hub.
(7) Remove the bearing cups from the hub bore.
Use a brass drift, or an appropriate removal tool, to
tap out the cups.
INSTALLATION
(1) Thoroughly clean both axle bearings and inte-
rior of the hub with an appropriate cleaning solvent.
(2) Install bearing cups with Installer 8151 and
Handle C-4171.
(3)Pack inner and outer bearings with
Mopar wheel bearing grease or equivalent.
(4) Apply grease to inner and outer bearing cup
surfaces.
(5) Install inner axle bearing in the hub.
(6) Installnewgrease seal in hub with Installer
8149 and Handle C-4171.(7) Inspect bearing and seal contact surfaces on
the axle tube for burrs/roughness. Remove all the
rough contact surfaces from the axle tube.
(8) Carefully slide the hub onto the axle.
CAUTION: Do not let grease seal contact axle tube
threads during installtion.
(9) Install outer axle bearing.
(10) Install hub bearing adjustment nut with
Socket DD-1241±JD.
(11) Tighten adjustment nut to 163-190 N´m (120-
140 ft. lbs.) while rotating the wheel. Then loosen
adjustment nut 1/8 to 1/3 of-a-turn to provide 0.025-
0.250mm (0.001-0.009 in.) wheel bearing end play.
(12) Tap locking wedge into the spindle keyway
and adjustment nut.
NOTE: Located locking wedge in a new position in
the adjustment nut.
(13) Install axle shaft and brake drum.
(14) Install the wheel and tire assembly.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Scribe a mark on the universal joint, pinion
yoke, and pinion shaft for reference.
(3) Disconnect the propeller shaft from the pinion
yoke. 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 pinion yoke three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Hold the yoke with Wrench 6719. Remove the
pinion shaft nut and washer.
(9) Remove the yoke with Remover C-452 (Fig. 22).
(10) Remove the pinion shaft seal with suitable
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.
Arbor Discs 6732
BR/BEREAR AXLE - 248RBI 3 - 125
REAR AXLE - 248RBI (Continued)

(11) Install the brake drums.
(12) Add gear lubricant to the differential housing,
if necessary. Refer to the Lubricant Specifications for
gear lubricant requirements.
(13) 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 tohousing 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.
Fig. 25 Check Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
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
BR/BEREAR AXLE - 248RBI 3 - 127
PINION SEAL (Continued)

(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)

(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)

(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)

ally utilizes a ramping action supplied by the cross
shafts to increase the force applied to the clutch
packs to increase the torque supplied to the non-slip-
ping wheel. Powr-lokydifferentials resist wheel spin
on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, operation is
normal. In extreme cases of differences of traction,
the wheel with the least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
3 - 142 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(10) Remove the pinion shaft seal with suitable
pry tool or slide-hammer mounted screw.
INSTALLATION
(1) Clean the seal contact surface in the housing
bore.
(2) Examine the splines on the pinion shaft for
burrs or wear. Remove any burrs and clean the shaft.
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(3) Apply a light coating of gear lubricant on the
lip of pinion seal.
(4) Install the new pinion shaft seal with an
appropriate installer.
(5) Position the pinion yoke on the end of the shaft
with the reference marks aligned.
(6) Seat yoke on pinion shaft with Installer D-191
and Yoke Holder 6719 (Fig. 23).
(7) Remove the tools and install the pinion yoke
washer and nut.
(8) Hold pinion yoke with Yoke Holder 6719 and
tighten shaft nut to 289-380 N´m (220-280 ft. lbs.)
(Fig. 24). Rotate pinion shaft several revolutions to
ensure the bearing rollers are seated.
(9) Rotate the pinion shaft using an inch pound
torque wrench. Rotating resistance torque should be
equal to the reading recorded, plus a small amount
for the drag the new seal will have (Fig. 25).
Fig. 23 Yoke Installation
1 - YOKE INSTALLER
2 - YOKE HOLDER
Fig. 24 Tightening Pinion Shaft Nut
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
Fig. 25 Check Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
BR/BEREAR AXLE - 267RBI 3 - 157
PINION SEAL (Continued)