DODGE RAM 2002 Service Repair Manual

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).
(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.
Fig. 26 Pinon Rotating Torque
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 27 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 28 SPREAD DIFFERENTIAL HOUSING
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
3 - 96 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL (Continued)

DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 30).
(3) Rotate differential side gears and remove pin-
ion mate gears and thrust washers (Fig. 31).(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. 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
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
Fig. 31 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
BR/BEREAR AXLE - 267RBI 3 - 97
DIFFERENTIAL (Continued)

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: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted 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).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 any identification tag.
Tighten the cover 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.
Fig. 32 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 33 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 34 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
3 - 98 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL (Continued)

(13) Install the fill hole plug and tighten to 34 N´m
(25 ft. lbs.).
(14) Remove support and lower vehicle.
DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING - POWR-LOKT
WARNING: WHEN SERVICING VEHICLES WITH A
POWR-LOKTDIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. THE AXLE CAN EXERT ENOUGH
FORCE IF ONE WHEEL IS IN CONTACT WITH A
SURFACE TO CAUSE THE VEHICLE TO MOVE.
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.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent to wheel studs.(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 36).
(6) If rotating torque is less than 22 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
The Powr-Loktdifferential has a two-piece cross
shaft and uses 2 disc and 3 plates for each clutch
pack. One plate and one disc in each clutch pack is
dished.
NOTE: Pay close attention to the clutch pack
arrangement during this procedure. Note the direc-
tion of the concave and convex side of the plates
and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 37).
(2) Remove the case attaching bolts and remove
the button cover half (Fig. 38).
(3) Remove top clutch pack (Fig. 39).
(4) Remove top side gear clutch ring.
(5) Remove top side gear.
(6) Remove pinion mate gears and cross shafts.
(7) Remove the same parts listed above from the
ring gear flange half of the case. Keep these parts
with the flange cover half for correct installation in
their original positions.
ASSEMBLY
The Powr-Loktdifferential has a two-piece cross
shaft and uses 2 disc and 3 plates for each clutch
pack. One plate and one disc in each clutch pack is
dished.
Fig. 35 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 36 POWR-LOK TEST -TYPICAL
1 - SPECIAL TOOL
2 - TORQUE WRENCH
BR/BEREAR AXLE - 267RBI 3 - 99
DIFFERENTIAL (Continued)

Fig. 39 POWR-LOK COMPONENTS
1 - FLANGE HALF
2 - CLUTCH RING
3 - SIDE GEAR
4 - PINION MATE GEAR
5 - SCREW
6 - BUTTON HALF7 - PINION MATE CROSS SHAFT
8 - DISHED DISC
9 - PLATE
10 - DISHED DISC
11 - PLATE
Fig. 37 CASE MARKED
1 - REFERENCE MARKS
Fig. 38 COVER HALF REMOVAL
1 - CLUTCH PLATES
2 - BUTTON HALF
3 - FLANGE HALF
3 - 100 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL - POWR-LOK (Continued)

NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
(1) Saturate the clutch plates with MopartHypoid
Gear Lubricant or Additive (Fig. 40). Assemble clutch
packs into the side gear plate in exactly the same
position as removed (Fig. 39).
(2) Line up the plate ears and install the assem-
bled pack into the flange half (Fig. 41). Ensure that
the clutch plate lugs enter the slots in the case. Also
ensure that the clutch pack bottoms out on the case.
(3) Install pinion mate shafts and pinion mate
gears (Fig. 42).Make sure shafts are correctly
installed according to the alignment marks.
(4) Lubricate and install the other side gear and
clutch pack (Fig. 41).
(5) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(6) Tighten body screws alternately and evenly.
Tighten screws to 89-94 N´m (65-70 ft. lbs.) (Fig. 43).
If bolt heads have 7 radial lines or the number 180
stamped on the head, tighten these bolts to 122-136
N´m (90-100 ft. lbs.).
Fig. 40 CLUTCH PACK PRE-LUBRICATION
1 - CLUTCH PLATES
2 - SIDE GEAR
3 - CLUTCH RING
Fig. 41 CLUTCH PACK INSTALLATION
1 - LUGS
2 - FLANGE HALF
3 - SIDE GEAR
Fig. 42 CLUTCH PACK
1 - CLUTCH PACK
2 - SIDE GEAR
3 - PINION GEARS AND MATE SHAFT
4 - ALIGNMENT MARKS
BR/BEREAR AXLE - 267RBI 3 - 101
DIFFERENTIAL - POWR-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. 44).
INSTALLATION
(1) Install differential side bearings with installer
C-4190 and Handle C-4171 (Fig. 45).
(2) Install differential case into the housing.
Fig. 44 DIFFERENTIAL CASE BEARING
1 - PULLER
2 - ADAPTERS
3 - STEP PLATE
4 - BEARING
5 - DIFFERENTIAL CASE
Fig. 45 CASE BEARING INSTALLER
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 43 CASE HALF INSTALLATION
1 - FIXTURE
2 - CASE BOLTS
3 - TORQUE WRENCH
3 - 102 REAR AXLE - 267RBIBR/BE
DIFFERENTIAL - POWR-LOK (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the matched pinion gear.
(1) Remove differential from axle housing.
(2) Place differential case in a vise with soft metal
jaw protectors. (Fig. 46)
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 46).
(5) Remove exciter ring from the differential case
with a brass drift and a hammer.
(6) Mark pinion yoke and propeller shaft for
installation alignment.
(7) Disconnect propeller shaft from pinion yoke.
Tie propeller shaft to underbody.
(8) Hold pinion yoke with Yoke Holder 6719A and
remove pinion yoke nut and washer.
(9) Remove pinion yoke from pinion with Remover
C-452 and Wrench C-3281 (Fig. 47).
(10) Remove pinion gear from housing (Fig. 48).
(11) Remove pinion seal with a slide hammer or
pry bar.
(12) Remove oil slinger, if equipped, and the front
pinion bearing.
(13) Remove front pinion bearing cup with
Remover D-158 and Handle C±4171 (Fig. 49).(14) Remove rear bearing cup with Remover D-162
and Handle C-4171 (Fig. 50).
(15) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters C-293-37 (Fig.
51).
(16) Remove pinion depth shims from the pinion
gear shaft and record thickness of the shims.
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 47 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 48 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
BR/BEREAR AXLE - 267RBI 3 - 103

INSTALLATION
(1) Apply Mopar Door Ease stick lubricant or
equivalent to the outside surface of bearing cups.(2) Install rear pinion bearing cup with Installer
C-111 and Handle C-4171 (Fig. 52) and verify cup is
seated.
Fig. 49 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 50 REAR BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 51 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
Fig. 52 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 104 REAR AXLE - 267RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

(3) Install front pinion bearing cup with Installer
D-146 and Handle C-4171 (Fig. 53) and verify cup is
seated.
(4) Install pinion front bearing and oil slinger, if
equipped. Apply a light coating of gear lubricant on
the lip of pinion seal.
(5) Install anewpinion seal with an appropriate
installer (Fig. 54).
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. If the ring and pinion gears are
replaced refer to Adjustments (Pinion Gear Depth )
to select the proper thickness shim.
(6) Place the proper thickness pinion depth shim
on the pinion gear.(7) Install rear bearing and oil slinger, if equipped
on the pinion gear with Installer C-3095-A and a
press (Fig. 55).
(8) Install original solid shims on pinion gears.
(9) Install yoke with Installer C-3718 and Yoke
Holder 6719A (Fig. 56).
(10) Install the yoke washer andnewnut on the
pinion gear. Tighten the nut to 298-380 N´m (220-280
ft. lbs.).
(11) Check bearing rotating torque with an inch
pound torque wrench (Fig. 57). Pinion rotating torque
should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2.3 to 5.1 N´m (20 to 45 in. lbs.).
(12) If rotating torque is less than the desired
rotating torque, remove the pinion yoke and decrease
the thickness of the solid shim pack if greater
increase shim pack. Changing the shim pack thick-
ness by 0.025 mm (0.001 in.) will change the rotating
torque approximately 0.9 N´m (8 in. lbs.).
Fig. 53 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 54 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 55 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
BR/BEREAR AXLE - 267RBI 3 - 105
PINION GEAR/RING GEAR/TONE RING (Continued)