Front differential DODGE RAM 2003 Service User Guide

(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow hammer to seat the differ-
ential dummy bearings to each side of the differential
housing (Fig. 13) and (Fig. 14).
(8) Install Pilot Stud C-3288-B in cover bolt hole
below ring gear.
(9) Attach Dial Indicator C-3339 to post and posi-
tion dial indicator plunger on a flat surface on a ring
gear bolt head (Fig. 15).
(10) Push and hold differential to the pinion gear
side of the housing (Fig. 16) and zero dial indicator.
(11) Push and hold differential case to the ring
gear side and record dial indicator reading (Fig. 17).
(12) Add the dial indicator reading to the starting
point shim thicknesses to determine the total shim
thickness necessary to achieve zero differential end
play.
(13) Add 0.2 mm (0.008 in) to the zero end play
total. This new total represents the shims needed to
preload the new differential case bearings.
(14) Rotate dial indicator out of the way on pilot
stud.
(15) Remove differential case, dummy bearings
and dummy shims from the housing.
(16) Install the pinion gear in the housing. Install
the companion flange and establish the correct pinion
rotating torque.(17) Install differential case and Dummy Bearings
in the housing with a single dummy shim on the ring
gear side of the axle and tighten retaining cap bolts.
Fig. 13 SEAT PINION GEAR SIDE
1 - DEAD-BLOW HAMMER
2 - HOUSING
3 - PINION GEAR SIDE
Fig. 14 SEAT RING GEAR SIDE
1 - HOUSING
2 - DEAD-BLOW HAMMER
3 - RING GEAR SIDE
Fig. 15 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL
2 - PILOT STUD
3 - DIAL INDICATOR
4 - HOUSING
3 - 26 FRONT AXLE - C205FDR
FRONT AXLE - C205F (Continued)

(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 15).
(19) Push and hold differential case toward pinion.(20) Zero dial indicator face to pointer.
(21) Push and hold differential case to ring gear
side of the housing.
(22) Record dial indicator reading.
(23) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. Add the resulting measure-
ment to the thickness of the single dummy shim.
This is the thickness of shim required to achieve
proper backlash.
(24) 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.
(25) Rotate dial indicator out of the way on pilot
stud.
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates
8142-A on the housing and spread open enough to
receive differential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the dial indicator plunger against a
ring gear tooth (Fig. 18).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
Fig. 16 ZERO DIAL INDICATOR
1 - PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
Fig. 17 RECORD DIAL INDICATOR
1 - DIAL INDICATOR
2 - HOUSING
3 - RING GEAR SIDE
Fig. 18 RING GEAR BACKLASH
1 - RING GEAR
2 - DIAL INDICATOR
DRFRONT AXLE - C205F 3 - 27
FRONT AXLE - C205F (Continued)

(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the differential housing to the
other (Fig. 19).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations 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 the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply the brakes lightly to create at 14 N´m
(10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:²Gear contact pattern correct (Fig. 20). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
21). Decrease backlash by moving the ring closer to
the pinion gear.
²Ring gear too close to pinion gear (Fig. 22).
Increase backlash, by moving the ring away from the
pinion gear.
Fig. 19 BACKLASH SHIM ADJUSTMENT
Fig. 20 CORRECT CONTACT PATTERN
Fig. 21 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
Fig. 22 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
3 - 28 FRONT AXLE - C205FDR
FRONT AXLE - C205F (Continued)

²Ring gear too far away from pinion gear (Fig.
23). Decrease backlash, by moving the ring closer to
the pinion gear.
²Ring gear too close to pinion gear (Fig. 24).
Increase backlash, by moving the ring away from the
pinion gear.²Pinion gear set too low (Fig. 25). Increase pinion
gear height, by increasing the pinion depth shim
thickness.
²Pinion gear set too high (Fig. 26). Decrease pin-
ion depth, by decreasing the pinion depth shim thick-
ness.
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.55, 3.92
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Ring Gear Diameter 205 mm (8.0 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - New Bearings 2.0-2.8 N´m (18-25 in. lbs.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Fig. 23 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 24 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 25 LOW PINION HEIGHT
Fig. 26 HIGH PINION HEIGHT
DRFRONT AXLE - C205F 3 - 29
FRONT AXLE - C205F (Continued)

TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Mounting Nuts 95 70 -
Differential Fill Hole Plug 34 25 -
Differential Cover Bolts 22 15 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Pinion Nut 271-475 200-350 -
SPECIAL TOOLS
PULLER C-293-PA
ADAPTER C-293-42
ADAPTER C-293-48
PLUG C-293-3
PULLER C-452
HOLDER 6719A
HANDLE C-4171
3 - 30 FRONT AXLE - C205FDR
FRONT AXLE - C205F (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove snap ring from the axle shaft.
(5) Remove axle with Remove 8420A Collar 8420-3
and Slide Hammer C-3752 (Fig. 27).
INSTALLATION
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
(3) Check the differential fluid level and add fluid
if necessary.
(4) Install skid plate, if necessary.
(5) Install half shaft.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal with a small pry bar.
INSTALLATION
(1) Clean axle shaft bore clean.
(2) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(3) Lubricate seal lip with gear lubricant.
(4) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(5) Install axle shaft O-ring.
(6) Check the differential fluid level and add fluid
if necessary.
(7) Install skid plate, if necessary.
(8) Install half shaft.
AXLE BEARINGS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal.
(7) Install axle shaft bearing Remover C-4660-A in
the bearing (Fig. 28). Then tighten the nut to spread
the remover in the bearing.
(8) Install the bearing remove cup, bearing and
nut (Fig. 29). Then tighten the nut to draw the bear-
ing out.
Fig. 27 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 28 BEARING REMOVER
1 - AXLE BEARING
2 - NUT
3 - REMOVER
DRFRONT AXLE - C205F 3 - 33

(9) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wipe the axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 5063
and Handle C-4171 (Fig. 30).
(3) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(4) Lubricate seal lip with gear lubricant.
(5) Insert axle shaft through seal, bearing and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.(6) Install axle shaft O-ring.
(7) Check the differential fluid level and add fluid
if necessary.
(8) Install skid plate, if necessary.
(9) Install half shaft.
PINION SEAL
REMOVAL
(1) Remove skid plate, if equipped.
(2) Remove both half shafts.
(3) Mark the propeller shaft and pinion companion
flange (Fig. 31) for installation reference.
(4) Remove the front propeller shaft.
(5) Rotate the pinion gear three or four times and
verify pinion rotates smoothly.
(6) Record pinion rotating torque with an inch
pound torque wrench, for installation reference (Fig.
32).
(7) Position Holder 6719 against the companion
flange and install a four bolts and washers into the
threaded holes and tighten the bolts.
(8) Remove the pinion nut.
(9) Remove the companion flange with Remover
C-452 (Fig. 33).
(10) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
Fig. 29 BEARING REMOVER CUP
1 - REMOVER CUP
2 - BEARING
3 - NUT
Fig. 30 BEARING INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 31 COMPANION FLANGE
1 - COMPANION FLANGE
2 - PROPELLER SHAFT
3 - FLANGE YOKE
4 - REFERENCE MARK
3 - 34 FRONT AXLE - C205FDR
AXLE BEARINGS (Continued)

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install seal with Installer 8695 and Handle
C-4171 (Fig. 34).
(3) Install companion flange onto the pinion with
Installer C-3718 and Holder 6719A.(4) Position holder against the companion flange
and install four bolts and washers into the threaded
holes. Tighten the bolt and washer so that the holder
is held to the flange.
(5) Install anewpinion nut onto the pinion shaft
and tighten the pinion nut until there is zero bearing
end-play (Fig. 35).
CAUTION: Do not exceed 271 N´m (200 ft. lbs.) the
minimum tightening torque when installing the
companion flange at this point. Damage to the col-
lapsible spacer or bearings may result.
Fig. 32 PINION ROTATING TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 33 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 COMPANION FLANGE HOLDER
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 35
PINION SEAL (Continued)

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.
(6) Record pinion rotating torque using an inch
pound torque wrench. The rotating torque should be
equal to the reading recorded during removal plus an
additional 0.56 N´m (5 in. lbs.) (Fig. 36).
(7) If rotating torque is low, tighten the pinion nut
in 6.8 N´m (5 ft. lbs.) increments until the proper
rotating torque is achieved.
CAUTION: If maximum tightening torque 475 N´m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Replace the collapsible
spacer.
(8) Install propeller shaft with reference marks
aligned.
(9) Add gear lubricant to differential housing if
necessary.
(10) Install half shafts and skid plate if equipped.DIFFERENTIAL
DESCRIPTION
The differential case is a one-piece design. The dif-
ferential pinion shaft is retained with a snap ring.
Differential bearing preload and ring gear backlash
is adjusted by the use of adjusters. The adjuster are
between the differential bearings and the differential
housing. Pinion bearing preload is set and main-
tained by the use of a collapsible spacer. The
stamped steel cover provides a means for inspection
and servicing the differential.
OPERATION
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig.
37).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
38). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
REMOVAL
(1) Remove differential housing cover and drain
fluid.
Fig. 36 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 37 DIFFERENTIAL-STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
3 - 36 FRONT AXLE - C205FDR
PINION SEAL (Continued)

(2) Remove axle shafts.
(3) Loosen bearing cap bolts.
NOTE: Differential bearing cap reference numbers
are stamped on caps and machined flat on the
housing. If reference numbers cannot be found,
make new marks for later reference.
(4) Install Adapter Plates 8142-A onto the housing.
(5) Install Spreader W-129-B onto the adapter
plates (Fig. 39) and tighten the turnbuckle finger-
tight.(6) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
(7) Spread the housing to remove the differential
case from the housing (Fig. 40). 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.
(8) Remove dial indicator.
(9) While holding the differential case in position,
remove bearing cap bolts and caps.
(10) Remove differential from the housing (Fig.
41). Ensure differential bearing cups and shims
remain in position on the differential bearings.
(11) Tag differential bearing cups and shims to
indicate their location.
(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 42).
(5) Remove the differential side gears and thrust
washers.
Fig. 38 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 39 ADAPTER PLATES AND SPREADER
1 - ADAPTER PLATE
2 - SPREADER
Fig. 40 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - SPREADER
DRFRONT AXLE - C205F 3 - 37
DIFFERENTIAL (Continued)