DODGE RAM 2003 Service Repair Manual

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 the hole in the pinion gear mate shaft
with the hole in the differential case.
(5) Install the roll-pin in the differential case a
punch and hammer (Fig. 43). Peen the edge of the
roll-pin hole in the differential case in two places
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
(7) Install ring gear.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader W-129-B with the Adapter
Plates 8142-A and install the safety holddown
clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
Fig. 41 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 42 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 43 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 38 FRONT AXLE - C205FDR
DIFFERENTIAL (Continued)

(3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove dial indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain in position on the
bearings and the differential preload shims are
seated in the housing. Tap differential case to ensure
bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader.
(8) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(9) Install axle shafts.
(10) Apply a bead of red Mopar Silicone Sealant or
equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N´m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-48 and
Plug C-293-3 (Fig. 44).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 45).
(2) Install differential into the housing.
Fig. 44 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
DRFRONT AXLE - C205F 3 - 39
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft jaw
(Fig. 46).
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 46).
(5) Mark the companion yoke and companion
flange for installation reference.
(6) Remove companion flange bolts and tie the pro-
peller shaft to the vehicle underbody.
(7) Rotate companion flange three or four times
and verify flange rotates smoothly.
(8) Record pinion rotating torque an inch pound
torque wrench for installation reference (Fig. 47).
(9) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(10) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so that
the Holder 6719 is held to the flange.
(11) Remove the pinion nut.
(12) Remove the companion flange with Remover
C-452 (Fig. 48).
(13) Remove pinion from differential housing.
(14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.(15) Remove oil slinger, if equipped and front pin-
ion bearing.
(16) Remove front pinion bearing cup with
Remover 8831 and Handle C-4171 (Fig. 49).
(17) Remove rear pinion bearing cup from housing
(Fig. 50) with Remover 8401 and Handle C-4171.
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 47 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 48 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
3 - 40 FRONT AXLE - C205FDR

(18) Remove collapsible preload spacer (Fig. 51).
(19) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-42 (Fig. 52).(20) Remove depth shims from the pinion shaft
and record thickness of shims.
Fig. 49 FRONT PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 50 REAR PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 51 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
Fig. 52 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
DRFRONT AXLE - C205F 3 - 41
PINION GEAR/RING GEAR (Continued)

INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer to Adjust-
ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of the bearing cups.
(2) Install rear pinion bearing cup with Installer
8692 and Driver Handle C-4171 (Fig. 53) and verify
cup is seated.(3) Install front pinion bearing cup with Installer
8693 and Handle C-4171 (Fig. 54) and verify cup is
seated.
(4) Lubricate front pinion bearing and install bear-
ing in the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal.
(6) Install pinion seal with Installer 8695 and
Handle C-4171 (Fig. 55).
Fig. 53 REAR PINION BEARING CUP
1 - HOUSING
2 - INSTALLER
3 - HANDLE
Fig. 54 FRONT PINION BEARING CUP
1 - HOUSING
2 - INSTALLER
3 - HANDLE
Fig. 55 PINION SEAL
1 - HANDLE
2 - INSTALLER
3 - 42 FRONT AXLE - C205FDR
PINION GEAR/RING GEAR (Continued)

(7) Place pinion depth shim (Fig. 56) on the pinion
shaft.
(8) Install rear pinion bearing onto the pinion
shaft with Installer 6448 and a press (Fig. 57).(9) Installnewcollapsible spacer onto the pinion
shaft (Fig. 58).
(10) Lubricate rear pinion bearing and install the
pinion gear in the housing.
(11) Install companion flange with Installer
C-3718 and Holder 6719.
(12) Installnewpinion nut and tighten to 271
N´m (200 ft. lbs.) (Fig. 59).
(13) Using Holder 6719 and a torque wrench set at
475 N´m (350 ft. lbs.). Tighten pinion nut until bear-
ing end play is taken up.
(14) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until desired rotating torque is achieved.
Measure rotating torque frequently to avoid over-
crushing the collapsible spacer (Fig. 60). The pinion
rotating torque should be:
²Original Bearings: 1 to 2.5 N´m (10 to 20 in.
lbs.)
²New Bearings: 2.0 to 2.8 N´m (18 to 25 in. lbs.)
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed.
(15) Invert differential case and start two ring
gear bolts to provide ring gear bolt hole alignment.
(16) Invert differential case in the vise.
Fig. 56 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 57 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 58 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
DRFRONT AXLE - C205F 3 - 43
PINION GEAR/RING GEAR (Continued)

(17) Installnewring gear bolts and alternately
tighten to 108 N´m (80 ft. lbs.) (Fig. 61).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(18) Install differential in housing and verify gear
mesh, backlash and contact pattern.
(19) Install differential cover and fill with gear
lubricant.
Fig. 59 PINION NUT
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 60 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 61 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
3 - 44 FRONT AXLE - C205FDR
PINION GEAR/RING GEAR (Continued)

FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page page
FRONT AXLE - 9 1/4 AA
DESCRIPTION.........................45
OPERATION...........................45
DIAGNOSIS AND TESTING................45
REMOVAL.............................48
INSTALLATION.........................48
ADJUSTMENTS........................49
SPECIFICATIONS.......................53
SPECIAL TOOLS.......................53
AXLE SHAFTS
REMOVAL.............................56
DISASSEMBLY.........................56
ASSEMBLY............................58
INSTALLATION.........................58
AXLE SHAFT SEALS
REMOVAL.............................58
INSTALLATION.........................58PINION SEAL
REMOVAL.............................60
INSTALLATION.........................60
DIFFERENTIAL
DESCRIPTION.........................61
OPERATION...........................61
REMOVAL.............................61
DISASSEMBLY.........................62
ASSEMBLY............................63
INSTALLATION.........................63
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................64
INSTALLATION.........................65
PINION GEAR/RING GEAR
REMOVAL.............................65
INSTALLATION.........................66
FRONT AXLE - 9 1/4 AA
DESCRIPTION
The axle consists of a cast iron center casting dif-
ferential housing with axle shaft tubes extending
from each side. The tubes are pressed into the differ-
ential housing and welded. The design has the cen-
terline of the pinion set above the centerline of the
ring gear. The axle has full-floating axle shafts,
meaning the shaft are supported by the hub bear-
ings. The axle has a vent used to relieve internal
pressure caused by lubricant vaporization and inter-
nal expansion.
OPERATION
The axle receives power from the front propeller
shaft. The 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.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, 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 mate shaft can also cause a
snapping 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
DRFRONT AXLE - 9 1/4 AA 3 - 45

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 front/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 vibration. Do
not overlook engine accessories, brackets and drive
belts.
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 - 46 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (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.
DRFRONT AXLE - 9 1/4 AA 3 - 47
FRONT AXLE - 9 1/4 AA (Continued)