clutch DODGE RAM 2002 Service Owner's Manual
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Page 162 of 2255
REAR AXLE - 286RBI
TABLE OF CONTENTS
page page
REAR AXLE - 286RBI
DESCRIPTION........................107
OPERATION..........................108
DIAGNOSIS AND TESTING - AXLE.........108
REMOVAL............................112
INSTALLATION........................112
ADJUSTMENTS.......................112
SPECIFICATIONS
REAR AXLE - 286RBI.................120
SPECIAL TOOLS
REAR AXLE - 286 RBI.................120
AXLE SHAFTS
REMOVAL............................123
INSTALLATION........................123
AXLE BEARINGS
REMOVAL............................123
INSTALLATION........................123
PINION SEAL
REMOVAL............................123INSTALLATION........................124
DIFFERENTIAL
REMOVAL............................125
DISASSEMBLY........................126
ASSEMBLY...........................126
INSTALLATION........................126
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT....128
DISASSEMBLY........................128
ASSEMBLY...........................129
DIFFERENTIAL CASE BEARINGS
REMOVAL............................129
INSTALLATION........................129
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................131
INSTALLATION........................132
REAR AXLE - 286RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housings
consist of an iron center casting (differential housing)
with axle shaft tubes extending from either side. The
tubes are pressed into the differential housing and
welded. The axles are full-floating axle shafts, that
are supported by the axle housing tubes. The full-
float axle shafts are retained by bolts attached to the
hub.
The differential case for the standard differential is
a one-piece design. Differential bearing preload and
ring gear backlash are adjusted by the use of shims
located between the differential bearing cones andcase. Outboard protective spacers are located
between the differential bearing cup and housing.
Pinion bearing preload is set and maintained by the
use of shims. Pinion height is controlled by a shim
pack located under the inner pinion bearing cup. The
differential cover provides a means for inspection and
service.
Axles equipped with a Trac-Loktdifferential are
optional. The differential contains two clutch packs,
four pinion gears, and a one-piece pinion mate cross
shaft to provide increased torque to the non-slipping
wheel in addition to the standard differential compo-
nents. A Trac-loktdifferential for the has a two-piece
differential case.
BR/BEREAR AXLE - 286RBI 3 - 107
Page 163 of 2255
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must travel
a greater distance than the inside wheel to complete a
turn. The difference must be compensated for to prevent
the tires from scuffing and skidding through turns. To
accomplish this, the differential allows the axle shafts
to turn at unequal speeds (Fig. 2). In this instance, the
input torque applied to the pinion gears is not divided
equally. The pinion gears now rotate around the pinion
mate shaft in opposite directions. This allows the side
gear and axle shaft attached to the outside wheel to
rotate at a faster speed.
TRAC-LOKŸ DIFFERENTIAL
The Trac-lokŸ clutches are engaged by two concur-
rent forces. The first being the preload force exerted
through Belleville spring washers within the clutch
packs. The second is the separating forces generatedby the side gears as torque is applied through the
ring gear (Fig. 3).
The Trac-lokŸ design provides the differential
action needed for turning corners and for driving
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. Trac-lokŸ differentials resist wheel
spin on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, Trac-lokŸ
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
Fig. 1 STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
Fig. 2 ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 108 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)
Page 164 of 2255
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 issimilar 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.
Fig. 3 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
BR/BEREAR AXLE - 286RBI 3 - 109
REAR AXLE - 286RBI (Continued)
Page 165 of 2255
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
3 - 110 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)
Page 166 of 2255
Condition Possible Causes Correction
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
BR/BEREAR AXLE - 286RBI 3 - 111
REAR AXLE - 286RBI (Continued)
Page 183 of 2255
(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 a Trac-lokŸ unit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-lokŸ
Lubricant (friction modifier) should be added after
repair service 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.
(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.
(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 Trac-Loktdifferential on this axle has a one-
piece cross shaft and uses one dished disc, regular 5
disc and 7 plates.
NOTE: Pay attention to the clutch pack arrangement
during disassembly. Note the direction of the con-
cave and convex side of the plates and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 35).
(2) Remove case attaching bolts and remove the
button cover half (Fig. 36).
(3) Remove top clutch pack.
(4) Remove top side gear clutch ring.(5) Remove top side gear.
(6) Remove pinion mate gears and cross shaft.
(7) Remove the same parts listed above from the
ring gear flange half of the case. Keep these parts
Fig. 35 CASE MARKED
1 - REFERENCE MARKS
Fig. 36 COVER HALF REMOVAL
1 - CLUTCH PLATES
2 - BUTTON HALF
3 - FLANGE HALF
3 - 128 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL (Continued)
Page 184 of 2255
with the flange cover half for installation in their
original positions.
ASSEMBLY
The Trac-Loktdifferential for this axle has a one-
piece cross shaft and uses one dished disc, 5 regular
disc and 7 plates for each clutch pack.
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubricate each component with gear lube before
assembly and installation.
(1) Saturate the clutch plates with Mopar Hypoid
Gear Lubricant or Additive.
(2) Assembly the discs and plates on the side gear
(Fig. 37) in the following order.
(a) Install dished disc on side gear.
(b) Install one disc on side gear.
(c) Install one plate on side gear.
(d) Install one disc on side gear.
(e) Install one plate on side gear.
(f) Install three discs on side gear.
(g) Install five plates on side gear.
(3) Line up the plate ears and install the assem-
bled pack into the flange half (Fig. 38). Verify clutch
plate lugs enter the slots in the case and clutch pack
bottoms out in the case.(4) Install pinion mate shafts and pinion mate
gears (Fig. 39).Verify shafts are correctly
installed according to the alignment marks.
(5) Lubricate and install the other side gear and
clutch pack (Fig. 38).
(6) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(7) Tighten body screws alternately and evenly to
122-136 N´m (90-100 ft. lbs.) (Fig. 40).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from the housing.
(2) Remove bearings from the differential case
with bridge and bearing splitter (Fig. 41).
INSTALLATION
(1) Install differential bearings with Installer
C-4190 and Handle C-4171 (Fig. 42).
(2) Install differential in the housing.
Fig. 37 CLUTCH PACK ASSEMBLY
1 - CLUTCH PLATES
2 - SIDE GEAR
3 - CLUTCH RING
Fig. 38 CLUTCH PACK
1 - LUGS
2 - FLANGE HALF
3 - SIDE GEAR
BR/BEREAR AXLE - 286RBI 3 - 129
DIFFERENTIAL - TRAC-LOK (Continued)
Page 185 of 2255
Fig. 39 CLUTCH PACK
1 - CLUTCH PACK
2 - SIDE GEAR
3 - PINION GEARS AND MATE SHAFT
4 - ALIGNMENT MARKS
Fig. 40 CASE HALF BOLTS
1 - FIXTURE
2 - CASE BOLTS
3 - TORQUE WRENCH
Fig. 41 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - DIFFERENTIAL
Fig. 42 CASE BEARING INSTALLER
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
3 - 130 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL CASE BEARINGS (Continued)
Page 232 of 2255
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
OPERATION............................2
WARNING.............................2
DIAGNOSIS AND TESTING - CLUTCH........2
SPECIFICATIONS - CLUTCH...............7
CLUTCH DISC
REMOVAL.............................7
INSTALLATION..........................8
CLUTCH HOUSING
DIAGNOSIS AND TESTING - CLUTCH
HOUSING............................9
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH RELEASE BEARING
REMOVAL.............................12
INSTALLATION.........................12FLYWHEEL
DIAGNOSIS AND TESTING - FLYWHEEL.....13
DISASSEMBLY.........................13
ASSEMBLY............................14
PILOT BEARING
REMOVAL.............................14
INSTALLATION.........................14
CLUTCH PEDAL
REMOVAL.............................15
INSTALLATION.........................15
LINKAGE
REMOVAL.............................15
INSTALLATION.........................16
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION.........................17
OPERATION...........................17
CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, dry-
type disc, diaphragm style pressure plate (Fig. 1) and
hydraulic linkage. The flywheel is bolted to the rear
flange of the crankshaft. The clutch pressure plate is
bolted to the flywheel with the clutch disc between
these two components. The clutch system provides
the mechanical, link between the engine and the
transmission. The system is designed to transfer the
torque output of the engine, to the transmission
while isolating the transmission from the engine fir-
ing pulses to minimize concerns such as gear rattle.
Fig. 1 ENGINE POWERFLOW
BR/BECLUTCH 6 - 1
Page 233 of 2255
OPERATION
When the clutch pedal is depressed, it actuates the
clutch master cylinder. This sends hydraulic pressure
to the clutch slave cylinder. The release fork is then
actuated by the slave cylinder mounted on the trans-
mission housing. The release fork pivots on a ball
stud mounted in the transmission housing and
pushes the release bearing. The release bearing then
depresses the pressure plate spring fingers, thereby
releasing pressure on the clutch disc and allowing
the engine crankshaft to spin independently of the
transmission input shaft (Fig. 2).
WARNING
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTSWITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
DIAGNOSIS AND TESTING - CLUTCH
A road test and component inspection (Fig. 3) is
recommended to determine a clutch problem.
During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
ranges and observe clutch action. If the clutch chat-
ters, grabs, slips or does not release properly, remove
and inspect the clutch components. If the problem is
noise or hard shifting, further diagnosis may be
needed as the transmission or another driveline com-
ponent may be at fault.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch
malfunctions. Oil, water or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter,
slip and grab.
During inspection, note if any components are con-
taminated with oil, hydraulic fluid or water/road
splash.
Oil contamination indicates a leak at either the
rear main seal or transmission input shaft. Oil leak-
age produces a residue of oil on the housing interior
and on the clutch cover and flywheel. Heat buildup
caused by slippage between the cover, disc and fly-
wheel, can sometimes bake the oil residue onto the
components. The glaze-like residue ranges in color
from amber to black.
Road splash contamination means dirt/water is
entering the clutch housing due to loose bolts, hous-
ing cracks or through hydraulic line openings. Driv-
ing through deep water puddles can force water/road
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave
cylinder push rod seals.
Fig. 2 CLUTCH OPERATION
1 - FLYWHEEL
2 - PRESSURE PLATE FINGERS
3 - PIVOT POINT
4 - RELEASE BEARING PUSHED IN
5 - CLUTCH DISC ENGAGED
6 - CLUTCH DISC ENGAGED
7 - RELEASE BEARING
6 - 2 CLUTCHBR/BE
CLUTCH (Continued)