DODGE RAM 2002 Service Owners Manual

(3) Install a new nut on the pinion gear. Tighten
the nut only enough to remove the shaft end play.
(4) Rotate the pinion shaft using an inch pound
torque wrench. Rotating torque should be equal to
the reading recorded during removal, plus an addi-
tional 0.56 N´m (5 in. lbs.) (Fig. 34).
(5) If the rotating torque is to low, use Holder 6719
to hold the pinion yoke (Fig. 35), and tighten the pin-
ion shaft nut in 6.8 N´m (5 ft. lbs.) until proper rotat-
ing torque is achieved.
(6) Align the installation reference marks and
attach the propeller shaft to the yoke.
(7) Check and add lubricant to axle, if necessary.
Refer to Lubricant Specifications in this section for
lubricant requirements.
(8) Install brake rotors and calipers.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
Fig. 31 Pinion
1 - YOKE HOLDER
2 - YOKE
3 - YOKE PULLER
Fig. 32 Pinion Seal Installation
1 - HANDLE
2 - INSTALLER
Fig. 33 PINION YOKE
1 - INSTALLER
2 - YOKE HOLDER
Fig. 34 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
3 - 36 FRONT AXLE - 248FBIBR/BE
PINION SEAL (Continued)

DIFFERENTIAL
REMOVAL
(1) Raise and support 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 hub bearings and axle shafts.
(6) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 36).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 37).
(9) Install the hold down clamps and tighten the
spreader turnbuckle finger-tight.
(10) Install Pilot Stud C-3288-B to 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 (Fig. 37) and zero the
dial indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 37).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If the housing is over-spread it could be
distorted or damaged.
(12) Remove the dial indicator.
Fig. 35 PINION SHAFT NUT
1 - PINION FLANGE
2 - YOKE HOLDER
3 - DIFFERENTIAL HOUSING
Fig. 36 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 37 SPREAD DIFFERENTIAL HOUSING
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
BR/BEFRONT AXLE - 248FBI 3 - 37
PINION SEAL (Continued)

(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. 38).
(14) Remove the case from housing.
(15) Remove and tag bearing cups to indicate their
location.
DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 39).
(3) Rotate differential side gears and remove pin-
ion mate gears and thrust washers (Fig. 40).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align hole in the pinion gear mate shaft with
hole in the differential case.
(5) Install and seat pinion mate shaft roll-pin in
the differential case and mate shaft with a punch
and hammer (Fig. 41). 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. 38 DIFFERENTIAL REMOVAL
1 - DIFFERENTIAL
2-PRYBAR
Fig. 39 PINION MATE SHAFT
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
Fig. 40 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
3 - 38 FRONT AXLE - 248FBIBR/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: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could be dis-
torted 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. 42).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 43) and tighten bearing cap bolts in a criss-
cross pattern to 109 N´m (80 ft. lbs.).
(8) Install axle shafts.
(9) Install the hub bearings.
Fig. 41 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 42 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 43 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
BR/BEFRONT AXLE - 248FBI 3 - 39
DIFFERENTIAL (Continued)

(10) Apply a bead of red Mopar Silicone Rubber
Sealant or equivalent to the housing cover (Fig. 44).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied or adhesion quality will be compro-
mised.
(11) Install the cover and tighten bolts in a criss-
cross pattern to 47 N´m (35 ft. lbs.).
(12) Fill the differential with Mopar Hypoid Gear
Lubricant or equivalent to bottom of the fill plug
hole.
(13) Install fill hole plug and tighten to 34 N´m (25
ft. lbs.).
(14) Remove support and lower vehicle.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 C-4487-1 (Fig. 45).
Fig. 44 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 45 Differential Bearing Removal
1 - PULLER
2 - ADAPTERS
3 - STEP PLATE
4 - BEARING
5 - DIFFERENTIAL CASE
3 - 40 FRONT AXLE - 248FBIBR/BE
DIFFERENTIAL (Continued)

INSTALLATION
(1) Install differential side bearings with Installer
C-4190 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the match pinion gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from differential case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 47).
(5) Mark pinion yoke and propeller shaft for
installation alignment.(6) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(7) Hold pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(8) Remove pinion yoke with Puller C-452 and
Flange Wrench C-3281 (Fig. 48).
Fig. 46 Install Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 47 RING GEAR
1 - CASE
2 - RING GEAR
3 - HAMMER
Fig. 48 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - PULLER
BR/BEFRONT AXLE - 248FBI 3 - 41
DIFFERENTIAL CASE BEARINGS (Continued)

(9) Remove pinion gear from housing (Fig. 49).
(10) Remove pinion seal with a pry bar or screw
mounted slide hammer.
(11) Remove oil slinger and front pinion bearing.
(12) Remove front pinion bearing cup with Driver
D-158 and Handle C-4171 (Fig. 50).(13) Remove rear bearing cup with remover D-162
and Handle C-4171 (Fig. 51).
(14) Remove collapsible preload spacer (Fig. 52).
Fig. 50 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 49 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
Fig. 51 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 52 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR BEARING
3 - 42 FRONT AXLE - 248FBIBR/BE
PINION GEAR/RING GEAR (Continued)

(15) Remove rear pinion bearing from pinion with
Puller C-293-PA and Adapters C-293-37 (Fig. 53).
(16) Remove pinion depth shims from the pinion
shaft and record thickness.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If ring and pinion
gears are reused, the original pinion depth shim
can be used. Refer to Adjustments (Pinion Gear
Depth) to select the proper shim thickness if ring
and pinion gears are replaced.
(1) Apply Mopar Door Ease stick lubricant or
equivalent to outside surface of bearing cups.
(2) Install rear pinion bearing cup with Installer
D-111 and Handle C-4171 (Fig. 54) and verify cup is
seated.
(3) Install front pinion bearing cup with Installer
D-146 and Handle C-4171 (Fig. 55) and verify cup is
seated.
(4) Install pinion front bearing, oil slinger. Apply a
light coating of gear lubricant on the lip of pinion
seal.
Fig. 53 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
Fig. 54 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 55 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
BR/BEFRONT AXLE - 248FBI 3 - 43
PINION GEAR/RING GEAR (Continued)

(5) Install pinion seal with an appropriate installer
(Fig. 56).
(6) Install proper thickness depth shim on the pin-
ion gear.
(7) Install rear bearing and oil slinger on pinion
gear with Installer C-3095-A (Fig. 57).
(8) Install anewcollapsible preload spacer on pin-
ion shaft (Fig. 58).
(9) Install pinion gear in housing.
(10) Install yoke with Installer C-3718 and Yoke
Holder 6719A (Fig. 59).
Fig. 56 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 57 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION REAR BEARING
Fig. 58 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR PINION BEARING
Fig. 59 PINION YOKE INSTALLER
1 - INSTALLER
2 - YOKE HOLDER
3 - 44 FRONT AXLE - 248FBIBR/BE
PINION GEAR/RING GEAR (Continued)

(11) Install yoke washer and anewnut on the
pinion gear. Tighten the nut to 291 N´m (215 ft. lbs.)
minimum.Do not over±tighten.Maximum torque
is 678 N´m (500 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion preload torque and never exceed specified
preload torque. If preload torque is exceeded a new
collapsible spacer must be installed.
(12) Use Yoke Holder 6719A to hold the yoke (Fig.
60) and tighten the nut in 6.8 N´m (5 ft. lbs.) until
the rotating torque is achieved. Measure the preload
torque frequently to avoid over-tightening the nut.
(13) Check bearing preload torque with an inch
pound torque wrench (Fig. 61). The torque to rotate
the pinion gear should be:
²Original Bearings: 1 to 2 N´m (10 to 20 in. lbs.).
²New Bearings: 2.26 to 4.52 N´m (20 to 40 in.
lbs.).
(14) Invert differential case in a vise and start two
ring gear bolts. This will provide case-to-ring gear
bolt hole alignment.
(15) Installnewring gear bolts and alternately
tighten to 176 N´m (130 ft. lbs.). (Fig. 62).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(16) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern).
(17) Install differential cover and fill with lubri-
cant.
Fig. 60 PINION NUT
1 - PINION FLANGE
2 - YOKE HOLDING
3 - DIFFERENTIAL HOUSING
Fig. 61 Pinion Rotating Torque
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 62 RING GEAR BOLT
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
BR/BEFRONT AXLE - 248FBI 3 - 45
PINION GEAR/RING GEAR (Continued)