DODGE RAM 2002 Service Repair Manual

SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.
(2) Remove factory installed shims from differen-
tial case.
(3) Install ring gear on differential case and
tighten bolts to specification.
(4) Install dummy side bearings D-343 on differen-
tial case.
(5) Install differential case in the housing.
(6) Install the marked bearing caps in their correct
positions and snug the bolts (Fig. 11).
(7) Using a dead-blow hammer, seat the differen-
tial dummy bearings to each side of the housing (Fig.
12) and (Fig. 13).
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 14).
(9) Attach the Dial Indicator C-3339 to pilot stud.
Position the dial indicator plunger on a flat surface
between the ring gear bolt heads (Fig. 14).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 15).
(11) Push and hold differential case to ring gear
side of the housing and record the dial indicator
reading (Fig. 16).
(12) Add 0.38 mm (0.015 in.) to the zero end play
total. This total represents the thickness of shims
needed to preload the new bearings when the differ-
ential is installed.(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.
(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and dummy bearings
D-343 in the housing (without shims), install bearing
caps and tighten bolts snug.
(17) Seat ring gear side dummy bearing (Fig. 13).
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 14).
Fig. 11 BEARING CAP BOLTS
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 12 SEAT PINION GEAR SIDE BEARING
1 - DEAD-BLOW HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 13 SEAT RING GEAR SIDE BEARING
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
3 - 86 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(19) Push and hold differential case toward pinion
gear and zero the dial indicator (Fig. 17).Fig. 14 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 DIAL INDICATOR LOCATION
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR ARM
4 - DIAL INDICATOR FACE
Fig. 16 DIFFERENTIAL CASE RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 17 DIFFERENTIAL CASE PINION GEAR SIDE
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
BR/BEREAR AXLE - 267RBI 3 - 87
REAR AXLE - 267RBI (Continued)

(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 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 read-
ing should be between 0.12 mm (0.005 in.) and 0.20 mm
(0.008 in.). If backlash is not within specifications trans-
fer the necessary amount of shim thickness 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 loca-
tions 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 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
1 - DIAL INDICATOR
Fig. 20 BACKLASH SHIM
3 - 88 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (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.
BR/BEREAR AXLE - 267RBI 3 - 89
REAR AXLE - 267RBI (Continued)

Fig. 21 GEAR TOOTH CONTACT PATTERNS
3 - 90 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

SPECIFICATIONS
REAR AXLE - 267RBI
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.55, 4.10
Ring Gear Diameter 267 mm (10.50 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard. Depth 136.53 mm (5.375 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 47 35 -
Bearing Cap Bolts 108 80 -
Ring Gear Bolt 176 130 -
Pinion Nut 298-380 220-280 -
Axle Shaft Bolts 129 95 -
Hub Bearing Nut 163-190 120-140 -
SPECIAL TOOLS
REAR AXLE - 267RBI
Puller 6790
Wrench DD-1241-JD
Installer 5064
Installer 8149
BR/BEREAR AXLE - 267RBI 3 - 91
REAR AXLE - 267RBI (Continued)

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-293-62
Installer C-4190
Handle C-4171
Fixture 6963-A
3 - 92 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

Remover D-158
Remover D-162
Adapters C-293-62
Installer D-111
Installer D-146
Installer C-3095-A
Installer C-3718
Trac-lok Tools 8139
Trac-lok Tools C-4487
Gauge Set 6730
Arbor Discs 6732
BR/BEREAR AXLE - 267RBI 3 - 93
REAR AXLE - 267RBI (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) 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).
Fig. 22 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
3 - 94 REAR AXLE - 267RBIBR/BE

(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 appropriate
installer.
(3) Install yoke with Installer D-191 and Yoke
Holder 6719A (Fig. 24).
(4) Install pinion yoke washer and nut.
(5) Hold pinion yoke with Yoke Holder 6719A and
tighten shaft nut to 289-380 N´m (220-280 ft. lbs.)
(Fig. 25). Rotate pinion shaft several revolutions to
ensure the bearing rollers are seated.
(6) 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. 26).
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.
(7) Install propeller shaft with the installation ref-
erence marks aligned.
(8) Install the brake drums.
(9) Add gear lubricant to the differential housing,
if necessary.
(10) Install wheel and tire assemblies and lower
the vehicle.
Fig. 23 PINION YOKE REMOVER
1 - PINION YOKE
2 - REMOVERFig. 24 PINION YOKE INSTALLER
1 - INSTALLER
2 - YOKE HOLDER
Fig. 25 TIGHTEN PINION NUT
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
BR/BEREAR AXLE - 267RBI 3 - 95
PINION SEAL (Continued)