rack and pinion DODGE RAM 2002 Service Repair Manual

CAUTION: Components attached with a nut and cot-
ter pin must be torqued to specification. Then if the
slot in the nut does not line up with the cotter pin
hole, tighten nut until it is aligned. Never loosen the
nut to align the cotter pin hole.
CAUTION: Suspension components with rubber
bushings (except stabilizer bar) should be tightened
with the vehicle at normal height. It is important to
have the springs supporting the weight of the vehi-
cle when the fasteners are torqued. If springs arenot at their normal ride position, vehicle ride com-
fort could be affected and premature bushing wear
may occur.
DESCRIPTION
The upper and lower suspension arms use bush-
ings to isolate road noise. The suspension arms are
bolted to the frame and axle through the rubber
bushings. The lower suspension arm uses cam bolts
at the axle to allow for caster and pinion angle
adjustment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut47 35 Ð
Shock Absorber
Lower Bolt135 100 Ð
Shock Absorber
Bracket75 55 Ð
Suspension Arm Lower
Axle Nut190 140 Ð
Suspension Arm Lower
Frame Nut190 140 Ð
Suspension Arm Upper
Axle Nut163 120 Ð
Suspension Arm Upper
Frame Nut163 120 Ð
Stabilizer Bar
Clamp Bolt54 40 Ð
Stabilizer Bar
Link Upper Nut37 27 Ð
Stabilizer Bar
Link Lower Nut47 35 Ð
Track Bar
Ball Stud Nut95 70 Ð
Track Bar
Axle Bracket Bolt176 130 Ð
Hub/Bearing
Nut245 180 Ð
Hub/Bearing
Bolts166 122 Ð
BR/BEFRONT - 4WD 2 - 15
FRONT - 4WD (Continued)

INSTALLATION
(1) Position front propeller shaft under vehicle
with rear universal joint over the transfer case com-
panion flange.
(2) Place front universal joint into the axle pinion
yoke.
(3) Align the mark on the flange yoke to the mark
on the transfer case companion flange.
(4) Loosely install bolts to hold universal joint to
transfer case companion flange.
(5) Align mark on front universal joint to the mark
on the axle pinion yoke.
(6) Install bolts to hold front universal joint to axle
pinion yoke. Tighten bolts to 19 N´m (14 ft. lbs.).
(7) Tighten bolts to hold universal joint to transfer
case companion flange to 88 N´m (65 ft. lbs.).
(8) Install skid plate, if equipped.
(9) Lower vehicle and road test to verify repair.
PROPELLER SHAFT - REAR
REMOVAL
(1) Shift transmission into Neutral.
(2) Raise and support vehicle on safety stands.
(3) Mark a line across the axle pinion yoke or com-
panion flange and propeller shaft or flange yoke for
installation reference.
(4) Mark the outline of the center bearing on the
frame crossmember for installation reference, if
equipped.
(5) Remove bolts that attach the center bearing to
the support bracket (Fig. 10), if equipped.
(6) Remove the bolts holding the universal joint
clamps to the pinion yoke (Fig. 11).
(7) Slide the slip yoke off of the transmission, or
transfer case, output shaft and remove the propeller
shaft (Fig. 11).
INSTALLATION
(1) Slide the slip yoke onto the transmission or
transfer case output shaft.
(2) Align the reference marks on the propeller
shaft yoke/flange yoke and pinion yoke/companion
flange.
(3) Align and install the center bearing to the sup-
port bracket, if necessary.
(4) Install the bolts and tighten to 68 N´m (50 ft.
lbs.).
(5) Position universal joint into pinion yoke and
tighten strap bolts to 29 N´m (22 ft. lbs.).
(6) Lower the vehicle.
Fig. 10 CENTER BEARING
1 - SUPPORT BRACKET
2 - CENTER BEARING
Fig. 11 REAR PROPELLER SHAFT
1 - SLIDING YOKE
2 - PROPELLER SHAFT
3 - PINION YOKE
4 - CLAMP
5 - SCREW
6 - OUTPUT SHAFT
BR/BEPROPELLER SHAFT 3 - 7
PROPELLER SHAFT - FRONT (Continued)

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:
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 rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
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.
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.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace as
necessary.
3 - 16 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

Condition Possible Causes Correction
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.
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.
BR/BEFRONT AXLE - 248FBI 3 - 17
FRONT AXLE - 248FBI (Continued)

Condition Possible Causes Correction
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.
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) Remove wheels and tires.
(3) Remove brake calipers and rotors. Refer to 5
Brakes for procedures.
(4) Remove ABS wheel speed sensors, if equipped.
Refer to 5 Brakes for procedures.
(5) Disconnect axle vent hose.
(6) Disconnect vacuum hose and electrical connec-
tor at disconnect housing.
(7) Remove front propeller shaft.
(8) Disconnect stabilizer bar links at the axle
brackets.
(9) Disconnect shock absorbers from axle brackets.
(10) Disconnect track bar from the axle bracket.
(11) Disconnect tie rod and drag link from the
steering knuckles.
(12) Position suitable lifting device under the axle
assembly.(13) Secure axle to lifting device.
(14) Mark suspension alignment cams for installa-
tion reference.
(15) Disconnect upper and lower suspension arms
from the axle bracket.
(16) Lower the axle. The coil springs will drop
with the axle.
(17) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur. Rubber bushings must never
be lubricated.
(1) Support the axle on a suitable lifting device.
3 - 18 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 37 N´m (27 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 88 N´m (65 ft. lbs.).
(11) Install ABS wheel speed sensors, if equipped.
Refer to 5 Brakes for procedures.
(12) Install rotors and brake calipers, refer to 5
Brakes for procedures.
(13) Connect the vent hose to the tube fitting.
(14) Connect vacuum hose and electrical connector
to disconnect housing.
(15) Install front propeller shaft.
(16) Check and add differential lubricant, if neces-
sary. Refer to Lubricant Specifications for lubricant
requirements.
(17) Install wheel and tire assemblies.
(18) Remove supports and lower the vehicle.
(19) Tighten upper suspension arm nuts at axle to
121 N´m (89 ft. lbs.). Tighten upper suspension arm
nuts at frame to 84 N´m (62 ft. lbs.).
(20) Tighten lower suspension arm nuts at axle to
84 N´m (62 ft. lbs.). Tighten the lower suspension
arm nuts at frame to 119 N´m (88 ft. lbs.).
(21) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(22) Check front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched sets
only. The identifying numbers for the ring and pinion
gear are etched into the face of each gear (Fig. 3). A
plus (+) number, minus (±) number or zero (0) is etched
into the face of 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 127 mm (5.00
in.). The standard depth provides the best gear tooth
contact pattern. Refer to Backlash and Contact Pattern
in this section for additional information.
Compensation for pinion depth variance is
achieved with a select shim/slinger. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 4).
Fig. 3 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 4 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/SLINGER
2 - DIFFERENTIAL BEARING SHIM
BR/BEFRONT AXLE - 248FBI 3 - 19
FRONT AXLE - 248FBI (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)

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.
BR/BEREAR AXLE - 248RBI 3 - 49
REAR AXLE - 248RBI (Continued)

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.
3 - 50 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

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) 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 into the face of each gear (Fig.
4). A plus (+) number, minus (±) number or zero (0) is
etched into the face of 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 cen-
ter line of the ring gear to the back face of the pinion
is 127 mm (5.00 in.). The standard depth provides
the best gear tooth contact pattern. Refer to Back-
lash and Contact Pattern in this section for addi-
tional information.
Compensation for pinion depth variance is
achieved with a select shim. The shims are placed
between the rear pinion bearing and the pinion 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.
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
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 248RBI 3 - 51
REAR AXLE - 248RBI (Continued)