DODGE RAM 2002 Service Repair Manual

(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. 32). 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.
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. 33).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 34) 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.
(10) Apply a bead of red Mopar Silicone Rubber
Sealant or equivalent to the housing cover (Fig. 35).
Fig. 31 PINION MATE/SIDE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEARFig. 32 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 66 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL (Continued)

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 - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
(friction modifier) should be added after repair ser-
vice 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.
(2) Raise one rear wheel until it is completely off
the ground.
Fig. 33 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 34 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 35 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
BR/BEREAR AXLE - 248RBI 3 - 67
DIFFERENTIAL (Continued)

(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. 36).
(6) If rotating torque is less than 41 N´m (56 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. 37).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft roll pin.
(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate C-6960-3 (Fig.
38).
Fig. 36 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 37 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 38 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 68 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (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.(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 pinion gears (Fig. 41).
Fig. 39 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
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
BR/BEREAR AXLE - 248RBI 3 - 69
DIFFERENTIAL - TRAC-LOK (Continued)

(10) Insert Turning Bar C-6960-2 into the pinion
mate 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 and dry
components 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.
(1) Lubricate each component with gear lubricant
before assembly.
(2) 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. 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. 42 PINION GEAR
1 - PINION GEARS
2 - TURNING BAR
3 - 70 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

(3) Position assembled clutch disc packs on the
side gear hubs.
(4) 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.
(5) Position the differential case on the Holding
Fixture 6965.
(6) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 46).
(7) Install the upper side gear and clutch disc pack
(Fig. 46).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.(11) Rotate case with Turning Bar C-6960-2 until
the pinion mate 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 pin-
ion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft roll pin. Peen the
edge of the roll pin hole in the case slightly in two
places 180É apart.
(17) Lubricate all differential components with
hypoid gear lubricant.
Fig. 45 Clutch Pack and Lower Side Gear
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
Fig. 46 Clutch Pack and Upper Side Gear
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - STEP PLATE - C-6960-3
BR/BEREAR AXLE - 248RBI 3 - 71
DIFFERENTIAL - TRAC-LOK (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from the 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) Install differential side bearings with installer
C-4190 and Handle C-4171 (Fig. 48).
(2) Install differential case into the housing.
Fig. 47 DIFFERENTIAL CASE BEARING
1 - PULLER
2 - ADAPTERS
3 - STEP PLATE
4 - BEARING
5 - DIFFERENTIAL CASE
Fig. 48 CASE BEARING INSTALLER
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
3 - 72 REAR AXLE - 248RBIBR/BE

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Remove differential from 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) Drive ring gear from the differential case with
a soft hammer (Fig. 49).
(5) Remove exciter ring from the differential case
by slowly tapping the ring with a brass drift.
(6) Mark pinion yoke and propeller shaft for
installation alignment.
(7) Disconnect propeller shaft from pinion yoke
and tie propeller shaft to underbody.
(8) Hold yoke with Yoke Holder 6719A and remove
pinion yoke nut and washer.
(9) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 50).
(10) Remove pinion gear from housing (Fig. 51).
(11) Remove pinion seal with a slide hammer or
suitable pry bar.
(12) Remove oil slinger, if equipped, and front pin-
ion bearing.
(13) Remove front pinion bearing cup with
Remover D-158 and Handle C±4171 (Fig. 52).(14) Remove rear bearing cup with Remover D-162
and Handle C-4171 (Fig. 53).
(15) Remove collapsible preload spacer (Fig. 54)
from pinion gears.
(16) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-37 (Fig. 55).
(17) Remove pinion depth shims from the pinion
shaft and record thickness of the depth shims.
Fig. 49 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 50 PINION YOKE REMOVER
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 51 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
BR/BEREAR AXLE - 248RBI 3 - 73

Fig. 52 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 53 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 54 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - PINION DEPTH SHIM
5 - REAR BEARING
Fig. 55 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION GEAR SHAFT
3 - 74 REAR AXLE - 248RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

INSTALLATION
(1) Apply Mopar Door Ease stick or equivalent
lubricant to outside surface of bearing cups.
(2) Install rear pinion bearing cup with Installer
D-111 and Handle C-4171 (Fig. 56) and verify cup is
seated.
(3)
Install front pinion bearing cup with Installer
D-146 and Handle C-4171 (Fig. 57) and verify cup is
seated.
(4) Install front pinion bearing and oil slinger, if
equipped.(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Installnewpinion seal with an
appropriate installer (Fig. 58).
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 pinion depth shim should not
require replacement. Refer to Adjustments (Pinion
Gear Depth) to select the proper thickness shim
before installing rear pinion bearing cone.
(6) Place the proper thickness pinion depth shim
on the pinion gear.
(7) Install rear pinion bearing on the pinion gear
with Installer C-3095-A (Fig. 59).
Fig. 59 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 56 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 57 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 58 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
BR/BEREAR AXLE - 248RBI 3 - 75
PINION GEAR/RING GEAR/TONE RING (Continued)