DODGE RAM 2003 Service Repair Manual

DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 32).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove dif-
ferential pinions and thrust washers (Fig. 33).
(4) Remove differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion and thrust washers.
(3) Install the pinion shaft.
(4) Align the hole in the pinion shaft with the hole
in the differential case and install the pinion shaft
lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position.
(2) Install differential assembly into the housing.
(3) Install differential bearing caps in their origi-
nal locations (Fig. 34).
(4) Install bearing cap bolts and tighten the upper
bolts to 14 N´m (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated.
(5) Perform the differential bearing preload and
adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tight-
ened to their final torque of 136 N´m (100 ft.lbs.)
before proceeding.
(6) Install axle shafts.
(7) Apply a 1/4 inch bead of red Mopar Silicone
Rubber Sealant or equivalent to the housing cover
(Fig. 35).
Fig. 32 SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 33 DIFFERENTIAL GEARS
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
Fig. 34 BEARING CAPS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - ADJUSTER LOCK
4 - BEARING CAP
3 - 88 REAR AXLE-91/4DR
DIFFERENTIAL (Continued)

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.
(8) Install the cover and any identification tag and
tighten cover bolts to 41 N´m (30 ft. lbs.).
(9) Fill differential with lubricant to bottom of the
fill plug hole. Refer to the Lubricant Specifications
for the correct quantity and type.
NOTE: Trac-lokŸ differential equipped vehicles
should be road tested by making 10 to 12 slow fig-
ure-eight turns. This maneuver will pump the lubri-
cant through the clutch discs to eliminate a
possible chatter noise complaint.
DIFFERENTIAL-TRAC-LOK
DESCRIPTION
The optional Trac-Loktdifferential case has a one-
piece design and the similar internal components as
a standard differential, plus two clutch disc pack-
s.The differential pinion mate shaft is retained with
a threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
use of a collapsible spacer. The removable differential
cover provides a means for inspection and service.
OPERATION
This differential clutches are engaged by two con-
current forces. The first being the preload force
exerted through Belleville spring washers within the
clutch packs. The second is the separating forces gen-erated by the side gears as torque is applied through
the ring gear (Fig. 36).
This 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. This
differential 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, Trac-loktoperation is normal. In
extreme cases of differences of traction, the wheel
with the least traction may spin.DIAGNOSIS AND TESTING
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
Fig. 35 COVER SEALANT
1 - SEALANT
2 - DIFFERENTIAL COVER
Fig. 36 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
DRREAR AXLE - 9 1/4 3 - 89
DIFFERENTIAL (Continued)

(friction modifier) should be added after repair ser-
vice 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 (Fig. 37).
(6) If rotating torque is less than 41 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Fixture 6965 in a vise and position the
differential case on the fixture (Fig. 38).
(2) Remove ring gear if the ring gear is to be
replaced.
(3) Remove pinion gear mate shaft lock screw.
(4) Remove pinion gear mate shaft with a drift and
hammer.(5) Install and lubricate Step Plate C-6960-3 (Fig.
39).
(6) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
Fig. 37 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 38 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 39 STEP PLATE
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
3 - 90 REAR AXLE-91/4DR
DIFFERENTIAL-TRAC-LOK (Continued)

(7) Position a small screw driver in slot of
Threaded Adapter Disc C-6960-1 (Fig. 40) to prevent
adapter from turning.
(8) Install Forcing Screw C-6960-4 and tighten
screw to 122 N´m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 41).(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 42).
(10) Insert Turning Bar C-6960-2 into the pinion
mate shaft hole in the case.
(11) Loosen Forcing Screw in small increments
until clutch pack tension is relieved. Then turn the
case with the turning bar (Fig. 43).
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
Fig. 40 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - LOWER DISC
5 - THREADED ROD
6 - UPPER DISC
Fig. 41 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - DIFFERENTIAL CASE
Fig. 42 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 43 TURNING BAR
1 - PINION GEARS
2 - TURNING BAR
DRREAR AXLE - 9 1/4 3 - 91
DIFFERENTIAL-TRAC-LOK (Continued)

(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in correct order during
removal (Fig. 44).
(16) Remove differential case from the Holding
Fixture. Remove side gear, clutch pack retainer and
clutch pack. Keep plates in correct order during
removal.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(1) Lubricate each component with gear lubricant
before assembly.
(2) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 45).
(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 46).
NOTE: Verify clutch pack retaining clips are in posi-
tion and seated in the case pockets.
(5) Position case on the Fixture 6965.
Fig. 44 SIDE GEARS AND CLUTCH DISCS
1 - DIFFERENTIAL CASE
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
Fig. 45 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 46 CLUTCH PACK AND LOWER SIDE GEAR
1 - DIFFERENTIAL CASE
2 - LOWER SIDE GEAR AND CLUTCH PACK
3 - 92 REAR AXLE-91/4DR
DIFFERENTIAL-TRAC-LOK (Continued)

(6) Install lubricated Step Plate C-6960-3 in lower
side gear.
(7) Install upper side gear and clutch disc pack
(Fig. 47).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in side gears and verify
pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until
pinion mate shaft holes in pinion gears align with
holes in case.
NOTE: If necessary, slightly tighten the forcing
screw in order to install the pinion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.(14) Remove forcing screw, step plate and threaded
adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 48).
Fig. 47 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 48 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
DRREAR AXLE - 9 1/4 3 - 93
DIFFERENTIAL-TRAC-LOK (Continued)

INSTALLATION
(1) Install differential side bearings with Installer
C-4213 and Handle C-4171 (Fig. 49).
(2) Install differential case into housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts.
(4) Remove differential from the differential hous-
ing.
(5) Place differential case in a vise with soft metal
jaw protectors..
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 50).(8) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(9) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
(11) Remove companion flange with Remover
C-452 (Fig. 51).
(12) Remove pinion gear from the housing (Fig.
52).
Fig. 49 DIFFERENTIAL CASE BEARING
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 50 RING GEAR
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 51 COMPANION FLANGE
1 - COMPANION FLANGE
2 - REMOVER
3 - 94 REAR AXLE-91/4DR
DIFFERENTIAL CASE BEARINGS (Continued)

(13) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
(14) Remove front pinion bearing and oil slinger if
equipped.
(15) Remove front pinion bearing cup with
Remover C-4345 and Handle C-4171 (Fig. 53).(16) Remove rear pinion bearing cup from housing
(Fig. 54) with Remover C-4307 and Handle C-4171.
(17) Remove collapsible spacer from the pinion
shaft (Fig. 55).
Fig. 52 PINION GEAR
1 - RAWHIDE HAMMER
Fig. 53 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 54 REAR PINION BEARING CUP
1 - DRIVER
2 - HANDLE
Fig. 55 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
DRREAR AXLE - 9 1/4 3 - 95
PINION GEAR/RING GEAR/TONE RING (Continued)

(18) Remove rear pinion bearing (Fig. 56) from the
pinion shaft with Puller C-293-PA and Adapters
C-293-37.
(19) Remove pinion depth shim (Fig. 57) from the
pinion shaft and record shim thickness.INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Do not replace one gear without
replacing 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 stick
lubricant to outside surface of the pinion bearing
cups.
(2) Install rear pinion bearing cup (Fig. 58) with
Installer C-4308 and Driver Handle C-4171 and ver-
ify cup is seated.
(3) Install front pinion bearing cup (Fig. 59) with
Installer D-129 and Handle C-4171 and verify cup is
seated.
(4) Lubricate and install front pinion bearing into
the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-4076-B
and Handle C-4735-1 (Fig. 60).
Fig. 56 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
Fig. 57 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 58 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 96 REAR AXLE-91/4DR
PINION GEAR/RING GEAR/TONE RING (Continued)

(6) Install pinion depth shim (Fig. 61) on the pin-
ion gear shaft.
(7) Install rear bearing on the pinion (Fig. 62) with
Installer C-3095-A and a press.
Fig. 59 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 60 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
3 - HOUSING
Fig. 61 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 62 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
DRREAR AXLE - 9 1/4 3 - 97
PINION GEAR/RING GEAR/TONE RING (Continued)