DODGE RAM 2002 Service Repair Manual

(20) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 18).
(21) This is the shim thickness needed on the ring
gear side of the differential case for proper backlash.
(22) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(23) Rotate dial indicator out of the way on pilot
stud.
(24) Remove differential case and dummy bearings
from the housing.
(25) Install the selected side bearing shims onto
the differential case hubs.
(26) Install side bearings on differential case hubs
with Install C-4487-1 and Handle C-4171.
(27) Install bearing cups on differential.
(28) Install Spreader W-129-B and some items
from Adapter Set 6987 on the housing and spread
open enough to receive differential case.CAUTION: Never spread housing over 0.50 mm
(0.020 in.). The housing can be damaged if over-
spread.
(29) Install differential case into the housing.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 19).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
20).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.
Fig. 18 DIFFERENTIAL CASE TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RING GEAR BACKLASH MEASUREMENT
1 - DIAL INDICATOR
3 - 56 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

GEAR CONTACT PATTERN
The ring and pinion gear contact patterns will
show if the pinion depth is correct. It will also show
if the ring gear backlash has been adjusted correctly.
The backlash can be adjusted within specifications to
achieve desired tooth contact patterns.
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on the ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
21)and adjust pinion depth and gear backlash as nec-
essary.
Fig. 20 BACKLASH SHIM
BR/BEREAR AXLE - 248RBI 3 - 57
REAR AXLE - 248RBI (Continued)

Fig. 21 GEAR TOOTH CONTACT PATTERNS
3 - 58 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

SPECIFICATIONS
REAR AXLE - 248RBI
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.55, 4.10
Ring Gear Diameter 248 mm (9.75 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 127.0 mm (5.000 in.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2.3-5.1 N´m (20-45 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Ring Gear Bolt 176 130 -
Pinion Nut 292-447 215-330 -
Axle Shaft Bolts 122-136 90-100 -
Hub Bearing Nut 163-190 120-140 -
SPECIAL TOOLS
REAR AXLE - 248RBI
Puller 6790
Wrench DD-1241-JD
Installer 5064
Installer D-111
BR/BEREAR AXLE - 248RBI 3 - 59
REAR AXLE - 248RBI (Continued)

Installer 8149
Holder 6719A
Puller C-452
Installer 8108
Spreader W-129-B
Pilot Studs C-3288-B
Dial Indicator C-3339
Puller/Press C-293-PA
Adapters C-293-37
Installer C-4190
3 - 60 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

Handle C-4171
Fixture 6963-A
Remover D-158
Remover D-162
Adapters C-293-37
Installer D-111
Installer D-146
Installer C-3095-A
Installer C-3718
Trac-lok Tools 8139
BR/BEREAR AXLE - 248RBI 3 - 61
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.
Trac-lok Tools C-4487
Gauge Set 6730
Arbor Discs 6732
3 - 62 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark universal joint, pinion yoke and shaft for
installation reference.
(3) Disconnect the propeller shaft from the pinion
yoke.
(4) Remove the wheel and tire assemblies.
(5) Remove brake calipers to prevent any drag
that may cause a false bearing preload torque mea-
surement.
(6) Rotate pinion yoke three or four times.
(7) Record pinion gear rotating torque with an
inch pound torque wrench (Fig. 22).
(8) Hold yoke with Yoke Holder 6719A and remove
the pinion shaft nut and washer.
(9) Remove yoke with Remover C-452 (Fig. 23).
(10) Remove pinion seal with pry tool or slide-
hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with an aproppriate
installer (Fig. 24).
(3) Install yoke on pinion shaft with Installer
C-3718 and Yoke Holder 6719.(4) Install pinion yoke washer with theconcave
surfaceagainst the yoke end.
(5) Installnewpinion nut.
CAUTION: Never exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer, if
equipped, or bearings may result.
(6) Hold pinion yoke with Yoke Holder 6719 and
tighten shaft nut to 291.5 N´m (215 ft. lbs.) (Fig. 25).
Rotate pinion shaft several revolutions to ensure the
bearing rollers are seated.
(7) Rotate pinion shaft with a inch pound 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. 26).
Fig. 22 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 23 PINION YOKE REMOVER
1 - PINION YOKE
2 - REMOVER
Fig. 24 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
BR/BEREAR AXLE - 248RBI 3 - 63

CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new pin-ion nut and collapsible spacer, if equipped, must be
installed.
(8) If rotating torque is low, use Yoke Holder 6719
to hold the pinion yoke (Fig. 25) and tighten the pin-
ion shaft 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.
(9) Install propeller shaft with reference marks
aligned.
(10) Add gear lubricant to the differential housing,
if necessary.
(11) Install wheel and tire assemblies and lower
the vehicle.
(12)
Pump the brake pedal before moving the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
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. 27).
Fig. 25 TIGHTEN PINION NUT
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
Fig. 26 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 27 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
3 - 64 REAR AXLE - 248RBIBR/BE
PINION SEAL (Continued)

(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 28).
(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 to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing (Fig. 28) and
zero the indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 28).
CAUTION: Never spread the housing over 0.50 mm
(0.020 in). If housing is over-spread, it could be dis-
torted or damaged.
(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. 29).
(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. 30).
(3) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 31).
Fig. 28 SPREAD DIFFERENTIAL HOUSING
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
Fig. 29 DIFFERENTIAL REMOVAL
1 - DIFFERENTIAL
2-PRYBAR
Fig. 30 PINION MATE SHAFT
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
BR/BEREAR AXLE - 248RBI 3 - 65
DIFFERENTIAL (Continued)