height DODGE RAM 2003 Service Owner's Manual

NOTE: Arbor should rotate freely in the arbor disc.
(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. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench8883 until they make contact with the differential
bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
Fig. 3 GAUGE TOOLS IN HOUSING
1. PINION HEIGHT BLOCK
2. PINION BLOCK
3. ARBOR
4. ARBOR DISCS
Fig. 4 PINION DEPTH MEASUREMENT
1. DIAL INDICATOR
2. ARBOR
3. SCOOTER BLOCK
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 50 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

²Ring gear too close to pinion gear (Fig. 9).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Ring gear too far away from pinion gear (Fig.
10). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 11).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Pinion gear set too low (Fig. 12). Increase pinion
gear height, by increasing the pinion depth shim
thickness.
²Pinion gear set too high (Fig. 13). Decrease pin-
ion depth, by decreasing the pinion depth shim thick-
ness.
Fig. 9 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
Fig. 10 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 11 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 12 LOW PINION HEIGHT
Fig. 13 HIGH PINION HEIGHT
3 - 52 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

sent 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 numberis positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 4).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8542 and rear pinion bearing onto Screw 6741
(Fig. 4).
(2) Insert assembled height gauge components,
rear bearing, and screw into the housing through
pinion bearing cups (Fig. 5).
(3) Install front pinion bearing and Cone-Nut 6740
hand tight (Fig. 4).
(4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 6).
Install differential bearing caps on arbor discs and
tighten cap bolts to 41 N´m (30 ft. lbs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 4). Hold scooter block in place and
zero the dial indicator. Tighten dial indicator face
lock screw.
Fig. 4 PINION DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
DRREAR AXLE - 9 1/4 3 - 75
REAR AXLE - 9 1/4 (Continued)

(7) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 7). Continue moving the dial probe to the crest
of the arbor bar and record the highest reading.
(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
marked on the shaft of the pinion. For example, if
the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
The following must be considered when adjusting
bearing preload and gear backlash:²The maximum ring gear backlash variation is
0.076 mm (0.003 in.).
²Mark the gears so the same teeth are meshed
during all backlash measurements.
²Maintain the torque while adjusting the bearing
preload and ring gear backlash.
²Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure.
Insufficient adjuster torque can result in excessive
differential case free-play and ring gear noise.
²Insufficient adjuster torque will not support the
ring gear correctly and can cause excessive differen-
tial case free-play and ring gear noise.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
²Maintain the gear teeth engaged (meshed) as
marked.
²The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
²Do this five to ten times each time the threaded
adjusters are adjusted.
(1) Throught the axle tube use Wrench C-4164 to
adjust each threaded adjuster inward until the differ-
ential bearing free-play is eliminated. Allow some
ring gear backlash approximately 0.25 mm (0.01 in.)
between the ring and pinion gear. Seat the bearing
cups with the procedure described above.
(2) Install dial indicator and position the plunger
against the drive side of a ring gear tooth (Fig. 8).
Measure the backlash at 4 positions, 90 degrees
apart around the ring gear. Locate and mark the
area of minimum backlash.
Fig. 5 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 6 PINION DEPTH TOOLS
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 7 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
3 - 76 REAR AXLE-91/4DR
REAR AXLE - 9 1/4 (Continued)

²Ring gear too close to pinion gear (Fig. 11).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Ring gear too far away from pinion gear (Fig.
12). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 13).
Increase backlash, by moving the ring away from the
pinion gear using the adjusters.
²Pinion gear set too low (Fig. 14). Increase pinion
gear height, by increasing the pinion depth shim
thickness.
²Pinion gear set too high (Fig. 15). Decrease pin-
ion depth, by decreasing the pinion depth shim thick-
ness.
SIDE GEAR CLEARANCE
When measuring side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install the axle shafts and C-locks and pinion
mate shaft.(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear
and differential housing on opposite sides of the hub
(Fig. 16).
(3) If side gear clearances is no more than 0.005
inch. Determine if the axle shaft is contacting the
pinion mate shaft.Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear.If the end of
Fig. 11 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
Fig. 12 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 13 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 14 LOW PINION HEIGHT
Fig. 15 HIGH PINION HEIGHT
3 - 78 REAR AXLE-91/4DR
REAR AXLE - 9 1/4 (Continued)

(10) Fill differential to specifications.
(11) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. Compensation for pinion depth variance is
achieved with a select shim. The shim is located
between the rear pinion bearing and the pinion gear
head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 1).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8899 and rear pinion bearing onto Screw 6741
(Fig. 1).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 2).
(3) Install front pinion bearing and install the
Cone-nut 6740 hand tight. Then check tool rotating
torque with an inch pound torque wrench. The rotat-ing torque should be 1.7-2.26 N´m (15-20 in. lbs.)
(Fig. 1).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 3).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 165 N´m (122 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
(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.
Fig. 1 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 2 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 3 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
3 - 104 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 (Fig. 6) until they make contact with the differ-
ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
Fig. 4 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 6 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
DRREAR AXLE - 10 1/2 AA 3 - 105
REAR AXLE - 10 1/2 AA (Continued)

²Ring gear too far away from pinion gear (Fig.
11). Decrease the backlash, by moving the ring closer
to the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 12).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.²Pinion gear is set too low (Fig. 13). Increase the
pinion gear height, by increasing the pinion depth
shim thickness.
²Pinion gear is set too high (Fig. 14). Decrease
the pinion depth, by decreasing the pinion depth
shim thickness.
Fig. 11 INCORRECT BACKLASH
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
Fig. 12 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 13 LOW PINION HEIGHT
Fig. 14 HIGH PINION HEIGHT
DRREAR AXLE - 10 1/2 AA 3 - 107
REAR AXLE - 10 1/2 AA (Continued)

(10) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. Compensation for pinion depth variance is
achieved with a select shim. The shim is located
between the rear pinion bearing and the pinion gear
head.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 1).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8897 and rear pinion bearing onto Screw 6741
(Fig. 1).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 2).
(3) Install front pinion bearing and install the
Cone-nut 6740 hand tight. Then check tool rotating
torque with an inch pound torque wrench. The rotat-
ing torque should be 1.7-2.26 N´m (15-20 in. lbs.).
(Fig. 1).(4) Place Arbor Discs 8289 on Arbor D-115-3 in
position in the housing side bearing cradles (Fig. 3).
(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 281 N´m (207 ft. lbs.).
NOTE: Arbor should rotate freely in the arbor discs.
(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.
Fig. 1 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 2 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 3 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
DRREAR AXLE - 11 1/2 AA 3 - 131
REAR AXLE - 11 1/2 AA (Continued)

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 (Fig. 6) until they make contact with the differ-
ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
Fig. 4 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 6 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
3 - 132 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11 1/2 AA (Continued)