light DODGE RAM 2002 Service User Guide

(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)

(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)

cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
3 - 48 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)

(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)

(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)

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)

torque supplied to the non-slipping wheel. The differ-
ential resist wheel spin on bumpy roads and provide
more pulling power when one wheel looses traction.
Pulling power is provided continuously until both
wheels loose traction. If both wheels slip due to
unequal traction, operation is normal. In extreme
cases of differences of traction, the wheel with the
least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
3 - 80 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(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)