differential DODGE RAM 2002 Service Workshop Manual

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)

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.
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.
BR/BEREAR AXLE - 267RBI 3 - 81
REAR AXLE - 267RBI (Continued)

Condition Possible Causes Correction
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.
REMOVAL
(1) Raise and support the vehicle.
(2) Position an axle lift under the axle and secure
it to the axle.
(3) Remove the wheels and tires.
(4) Remove RWAL sensor from the differential
housing, if necessary.
(5) Remove brake hose from the axle junction
block.
(6) Disconnect parking brake cables and cable
brackets.
(7) Remove vent hose from the axle shaft tube.(8) Mark propeller shaft and yoke for installation
alignment reference.
(9) Remove propeller shaft.
(10) Remove shock absorbers from the axle brack-
ets.
(11) Remove spring clamps and spring brackets.
(12) Remove axle from the vehicle.
INSTALLATION
(1) Raise axle with lift and align to the leaf spring
centering bolts.
(2) Install spring clamps and spring brackets.
3 - 82 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(3) Install shock absorbers and tighten to specifica-
tions.
(4) Install RWAL sensor to the differential hous-
ing, if necessary.
(5) Install parking brake cables and cable brackets
(6) Install brake hose to the axle junction block.
(7) Install axle vent hose.
(8) Install propeller shaft with reference marks
aligned.
(9) Install wheels and tires assemblies.
(10) Add gear lubricant, if necessary.
(11) Remove lift from the axle and lower the vehi-
cle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched onto each gear (Fig. 4). A plus
(+) number, minus (±) number or zero (0) is etched
onto the pinion gear. This number is the amount (in
thousandths of an inch) the depth varies from the
standard depth setting of a pinion etched with a (0).
The standard setting from the center line of the ring
gear to the back face of the pinion is 136.53 mm
(5.375 in.). The standard depth provides the best
gear tooth contact pattern. Refer to Backlash and
Contact Pattern in this section for additional infor-
mation.
Compensation for pinion depth variance is
achieved with a select shim/oil baffle. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 5).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.Fig. 4 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 267RBI 3 - 83
REAR AXLE - 267RBI (Continued)

(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim/oil baffle equal to the dial indica-
tor reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 4). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Differential side bearing preload and gear backlash is
achieved by selective shims positioned behind the differ-
ential side bearing cones. The proper shim thickness
can be determined using slip-fit Dummy Bearings D-343
in place of the differential side bearings and a Dial Indi-
cator C-3339. Before proceeding with the differential
bearing preload and gear backlash measurements, mea-
sure the pinion gear depth and prepare the pinion for
installation. Establishing proper pinion gear depth is
essential to establishing gear backlash and tooth con-
tact patterns. After the overall shim thickness to take
up differential side play is measured, the pinion is
installed, and the gear backlash shim thickness is mea-
sured. The overall shim thickness is the total of the dial
indicator reading and the preload specification addedtogether. The gear backlash measurement determines
the thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the differ-
ential (Fig. 10). Differential shim measurements are
performed with spreader W-129-B removed.
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 267RBI 3 - 85
REAR AXLE - 267RBI (Continued)

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)

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)