DODGE RAM 2002 Service Workshop Manual

SPRING AND SHOCK ABSORBER
CONDITION POSSIBLE CAUSES CORRECTION
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Lower Nut136 100 Ð
Shock Absorber
Upper Nut136 100 Ð
Spring Clamp Nuts
6,010-10,500 GVW149 110 Ð
Spring Clamp Nuts
11,000 GVW Cab-Chassis163 120 Ð
Spring Front and Rear
Eye and Shackle
Bolt/Nut 6,010-6,400 GVW163 120 Ð
Spring Front and Rear
Eye and Shackle
Bolt/Nut 8,800-11,000
GVW176 130 Ð
Stabilizer Bar
Retainer Nuts54 40 Ð
Stabilizer Bar
Link Ball Stud Nut68 50 Ð
Stabilizer Bar
Link Upper Nut68 50 Ð
Stabilizer Bar
Frame Bracket Nuts54 40 Ð
Jounce Bumper
Bolts61 45 Ð
2 - 26 REARBR/BE
REAR (Continued)

SPECIAL TOOLS
SUSPENSION-REAR
BUSHINGS
REMOVAL
(1) Remove the spring from the vehicle.
(2) Position the spring eye in a press.
(3) Press the bushing out with an appropriate size
driver.
INSTALLATION
(1) Press new bushing into the spring eye with an
appropriate size driver. The bushing should be cen-
tered in the spring eye.
(2) Install the spring on the vehicle.
SHOCK
REMOVAL
(1) Raise vehicle and support axle.
(2) Remove the bolt and flag nut from the frame
crossmember bracket (Fig. 1).
(3) Remove the bolt and nut from the axle bracket.
(4) Remove the rear shock absorber from the vehi-
cle.
INSTALLATION
(1) Position the shock absorber in the brackets.
(2) Install the bolts through the brackets and the
shock. Install the flag nut on the top bolt and nut on
lower bolt.
(3) Tighten the upper and lower bolt/nuts Tighten
to 136 N.m (100 ft. lbs.)
(4) Remove the support and lower the vehicle.
SPRING
REMOVAL
(1) Raise the vehicle and support the axle to
remove all weight from the springs.
(2) Remove the nuts and spring clamp bolts that
attach the spring to the axle (Fig. 2) and (Fig. 3)and
(Fig. 4).
(3) Remove the nuts and bolts from the spring
front and rear shackle eyes.Note: To remove front
eye bolt on left side spring fuel tank must be
removed, (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/FUEL TANK - REMOVAL).
(4) Remove the spring from the vehicle.
(5) Remove the shackle from the spring.
Puller C-3894-A
Fig. 1 Shock Absorber
1 - FLAG NUT
2 - AXLE
3 - SHOCK
BR/BEREAR 2 - 27
REAR (Continued)

INSTALLATION
(1) Install shackle on rear spring eye and install
bolt and nut.(2) Position spring on axle shaft tube so spring
center bolt is inserted into the locating hole in the
axle tube spring pad or spacer.
(3) Align spring front eye with bolt hole in the
front bracket. Install the eye pivot bolt and nut.
(4) Align shackle eye with bolt hole in rear
bracket. Install bolt and nut.
(5) Tighten the spring front and rear eye pivot bolt
snug do not torque.
(6) Install spring clamp bolts and the retaining
nuts.
(7) Align the auxiliary spring with the primary
spring if equipped. Tighten the nuts until they force
the plate flush against the axle tube.
(8) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
(9) Tighten the spring clamp retaining nuts to
specifications
(10) Tighten spring front and rear eye pivot bolt
nuts and shackle eye to specifications.
Fig. 2 Rear Spring - 4x2
1 - SPRING CLAMP BOLTS
2 - SPRING SEAT
3 - SPRING
4 - SHACKLE
5 - SPRING PLATE
Fig. 3 Rear Spring - 4x4
1 - SPRING CLAMP BOLT
2 - SPRING SEAT
3 - SPRING
4 - SHACKLE
5 - SPRING PLATE
6 - SPACER
Fig. 4 Rear Spring - Cab-Chassis 11000 GVW
1 - SPRING CLAMP BOLT
2 - SPRING SEAT
3 - AUXILIARY SPRING
4 - SPRING
5 - SHACKLE
6 - SPRING PLATE
7 - SPACER
2 - 28 REARBR/BE
SPRING (Continued)

STABILIZER BAR
REMOVAL
(1) Raise and support vehicle.
(2) Remove nuts from the links at the stabilizer
bar and separate the links with Puller C-3894-A (Fig.
5).
(3) Remove stabilizer bar retainer nuts and retain-
ers (Fig. 6).
(4) Remove stabilizer bar and replace worn,
cracked or distorted bushings.
(5) Remove links upper mounting nuts and bolts
and remove links.
INSTALLATION
(1) Install link into frame brackets and install
mounting nuts and bolts.
(2) Install the stabilizer bar and center it with
equal spacing on both sides. Install stabilizer bar
retainers and tighten nuts to 54 N´m (40 ft. lbs.).
(3) Install stabilizer link ball studs into the bar
and tighten nuts to 68 N´m (50 ft. lbs.).
(4) Remove support and lower vehicle.
(5) Tighten upper link mounting nuts to 68 N´m
(50 ft. lbs.).
Fig. 5 Stabilizer Link
1 - LINK
2 - PULLER
Fig. 6 Stabilizer Bar Mounting Bolts And
1 - STABILIZER BAR
2 - RETAINERS
BR/BEREAR 2 - 29

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT......................1
FRONT AXLE - 248FBI....................14
REAR AXLE - 248RBI.....................46REAR AXLE - 267RBI.....................78
REAR AXLE - 286RBI....................107
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT...............................1
STANDARD PROCEDURES................3
SPECIFICATIONS
PROPELLER SHAFT....................6
SPECIAL TOOLS
PROPELLER SHAFT....................6
PROPELLER SHAFT - FRONT
REMOVAL.............................6
INSTALLATION..........................7
PROPELLER SHAFT - REAR
REMOVAL.............................7INSTALLATION..........................7
CENTER BEARING
REMOVAL.............................8
INSTALLATION..........................8
ADJUSTMENTS
ADJUSTMENT - CENTER BEARING........8
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY..........................8
ASSEMBLY.............................9
DOUBLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY.........................10
ASSEMBLY............................11
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Tires that are out-of-round or wheels that are
unbalanced will cause a low frequency vibration.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
Brake drums that are unbalanced will cause a
harsh, low frequency vibration. (Refer to 5 - BRAKES
- DIAGNOSIS AND TESTING)Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
joints or an incorrect propeller shaft angle, are usu-
ally the cause of such a vibration.
BR/BEDIFFERENTIAL & DRIVELINE 3 - 1

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds and bent areas.If the propel-
ler shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, properly installed and correctly aligned
with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 1).
(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 2) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/2 inch above and
below the mark). Repeat the vibration test (Fig. 3).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
3 - 2 PROPELLER SHAFTBR/BE
PROPELLER SHAFT (Continued)

(15) If the vibration remains unacceptable, apply
the same steps to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.
RUNOUT
(1) Remove dirt, rust, paint and undercoating from
the propeller shaft surface where the dial indicator
will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft sufficiently far away from weld areas to ensure
that the effects of the weld process will not enter into
the measurements.
(4) Refer to Runout Specifications chart.
(5) If propeller shaft runout is out of specification,
remove the propeller shaft, index the shaft 180É and
re-install the propeller shaft. Measure shaft runout
again.
(6) If propeller shaft runout is now within specifi-
cations, mark the shaft and yokes for proper orienta-
tion.
(7) If the propeller shaft runout is not within spec-
ifications, verify that the runout of the transmission/
transfer case and axle are within specifications.
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURES
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn.
(1) Remove any external bearing snap rings, if
equipped from universal joint so protractor base sits
flat.
(2) Rotate the shaft until transmission/transfer
case output yoke bearing is facing downward.
NOTE: Always make measurements from front to
rear and from the same side of the vehicle.
Fig. 1 Clamp Screw At Position 1
1 - CLAMP
2 - SCREWDRIVER
Fig. 2 Two Clamp Screws At The Same Position
Fig. 3 Clamp Screws Separated
1 - ó INCH
BR/BEPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)

(3) Place Inclinometer 7663 on yoke bearing (A)
parallel to the shaft (Fig. 4). Center bubble in sight
glass and record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(4) Rotate propeller shaft 90 degrees and place
Inclinometer on yoke bearing parallel to the shaft
(Fig. 5). Center bubble in sight glass and record mea-
surement. This measurement can also be taken at
the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(5) Subtract smaller figure from larger (C minus
A) to obtain Transmission Output Operating Angle.
(6) Rotate propeller shaft 90 degrees and place
Inclinometer on pinion yoke bearing parallel to the
shaft (Fig. 6). Center bubble in sight glass and record
measurement.
This measurement will give you the pinion
shaft or Input Yoke Angle (B).
(7) Subtract smaller figure from larger (C minus
B) to obtain axle Input Operating Angle.
Refer to rules given below and the example in (Fig.
7) for additional information.
²Good cancellation of U-joint operating angles
(within 1É).
²Operating angles less than 3É.
²At least 1/2 of one degree continuous operating
(propeller shaft) angle.
TWO-PIECE PROPELLER SHAFT
The procedure to measure the propeller shaft
angles involved with a two-piece (Fig. 8) propeller
shaft is the same as those for a one-piece propeller
shaft.
Fig. 4 Front (Output) Angle Measurement (A)
1 - SLIP YOKE BEARING CAP
2 - INCLINOMETER
Fig. 5 Propeller Shaft Angle Measurement (C)
1 - SHAFT YOKE BEARING CAP
2 - INCLINOMETER
Fig. 6 Rear (Input) Angle Measurement (B)
1 - PINION YOKE BEARING CAP
2 - INCLINOMETER
3 - 4 PROPELLER SHAFTBR/BE
PROPELLER SHAFT (Continued)

Fig. 7 Universal Joint Angle Example
1 - 4.9É Angle (C)
2 - 3.2É Angle (B)
3 - Input Yoke4 - 3.0É Angle (A)
5 - Output Yoke
Fig. 8 Universal Joint Angle Two-Piece Shaft
1 - YOKES MUST BE IN SAME PLANE
BR/BEPROPELLER SHAFT 3 - 5
PROPELLER SHAFT (Continued)