2001 DODGE RAM rear diff

NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Place Scooter Block/Dial Indicator in position
in the housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 6). Hold scooter block in place and
zero the dial indicator face to the pointer. Tighten
dial indicator face lock screw.
(8) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
(9) 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. 9). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(10) Select a shim/oil baffle equal to the dial indi-
cator reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 4). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
Fig. 6 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. 7 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 8 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
BR/BEFRONT AXLE - 216FBI 3 - 19
FRONT AXLE - 216FBI (Continued)

(7) Using a dead-blow hammer, seat the differen-
tial dummy bearings to each side of the housing (Fig.
12) and (Fig. 13).
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 14).
(9) Attach the Dial Indicator C-3339 to pilot stud.
Position the dial indicator plunger on a flat surface
between the ring gear bolt heads (Fig. 14).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 15).(11) Push and hold differential case to ring gear
side of the housing and record the dial indicator
reading (Fig. 16).
(12) Add 0.38 mm (0.015 in.) to the zero end play
total. This total represents the thickness of shims
Fig. 12 Seat Pinion Gear Side Dummy Bearing
1 - DEAD-BLOW HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 13 Seat Ring Gear Side Differential Dummy
Bearing
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
Fig. 14 Differential Side Play Measurement
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 Dial Indicator Location
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR ARM
4 - DIAL INDICATOR FACE
BR/BEFRONT AXLE - 216FBI 3 - 21
FRONT AXLE - 216FBI (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are serviced as a
matched set. Never replace one gear without replac-
ing the other gear.
(1) Raise and support the vehcile.
(2) Mark pinion yoke and propeller shaft for
installation reference.
(3) Disconnect propeller shaft from pinion yoke
and tie propeller shaft to underbody.
(4) Remove differential from the housing.
(5) Secure differential case in a vise with soft
metal jaw.
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 48).
(8) Hold yoke with Holder 6719A and remove pin-
ion nut and washer.
(9) Remove pinion yoke from the pinion shaft with
Puller C-452 and Flange Wrench C-3281 (Fig. 49).
(10) Remove pinion gear from housing (Fig. 50).
(11) Remove pinion seal with a pry bar or slide
hammer mounted screw.(12) Remove front pinion bearing and oil slinger.
(13) Remove front pinion bearing cup with
Remover D-147 and Handle C-4171 (Fig. 51).
(14) Remove rear bearing cup (Fig. 52) with
Remover D-149 and Handle C-4171.
(15) Remove collapsible preload spacer from pinion
shaft (Fig. 53).
(16) Remove rear pinion bearing with Puller
C-293-PA and Adapters C-293-40 (Fig. 54).
(17) Remove pinion depth shims from pinion shaft
and record thickness.
Fig. 47 Differential Bearing Installer
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 48 Ring Gear
1 - CASE
2 - RING GEAR
3- HAMMER
Fig. 49 Pinion Yoke
1 - YOKE HOLDER
2 - YOKE
3 - YOKE PULLER
3 - 40 FRONT AXLE - 216FBIBR/BE
DIFFERENTIAL CASE BEARINGS (Continued)

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
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:
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.
BR/BEFRONT AXLE - 248FBI 3 - 47
FRONT AXLE - 248FBI (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheels and tires.
(3) Remove the brake calipers and rotors. Refer to
Group 5, Brakes, for proper procedures.
(4) Remove ABS wheel speed sensors, if equipped.
Refer to Group 5, Brakes, for proper procedures.
(5) Disconnect the axle vent hose.
(6) Disconnect vacuum hose and electrical connec-
tor at disconnect housing.
(7) Remove the front propeller shaft.
(8) Disconnect the stabilizer bar links at the axle
brackets.
(9) Disconnect the shock absorbers from axle
brackets.
(10) Disconnect the track bar from the axle
bracket.
(11) Disconnect the tie rod and drag link from the
steering knuckles.
(12) Position the axle with a suitable lifting device
under the axle assembly.
(13) Secure axle to lifting device.
(14) Mark suspension alignment cams for installa-
tion reference.
(15) Disconnect the 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.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install the springs, retainer clip and bolts.
(5) Raise the axle and align it with the spring
pads.
(6) Position the 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 the track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install the shock absorber and tighten bolts to
121 N´m (89 ft. lbs.) torque.(9) Install the stabilizer bar link to the axle
bracket. Tighten the nut to 37 N´m (27 ft. lbs.)
torque.
(10) Install the drag link and tie rod to the steer-
ing knuckles and tighten the nuts to 88 N´m (65 ft.
lbs.) torque.
(11) Install the ABS wheel speed sensors, if
equipped. Refer to group 5, Brakes, for proper proce-
dures.
(12) Install the brake calipers and rotors. Refer to
Group 5, Brakes, for proper 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 in this section
for lubricant requirements.
(17) Install the wheel and tire assemblies.
(18) Remove the supports and lower the vehicle.
(19) Tighten the upper suspension arm nuts at
axle to 121 N´m (89 ft. lbs.) torque. Tighten the
upper suspension arm nuts at frame to 84 N´m (62 ft.
lbs.) torque.
(20) Tighten the lower suspension arm nuts at
axle to 84 N´m (62 ft. lbs.) torque. Tighten the lower
suspension arm nuts at frame to 119 N´m (88 ft. lbs.)
torque.
(21) Tighten the track bar bolt at the axle bracket
to 176 N´m (130 ft. lbs.) torque.
(22) Check the 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.
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/oil baffle. The shims are
placed between the rear pinion bearing and the pin-
ion 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.
3 - 50 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent 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
þ4 þ3 þ2 þ1 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 0 þ0.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 þ0.001 þ0.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 0 þ0.001 þ0.002 þ0.003
0+0.004 +0.003 +0.002 +0.001 0 þ0.001 þ0.002 þ0.003 þ0.004
þ1+0.003 +0.002 +0.001 0 þ0.001 þ0.002 þ0.003 þ0.004 þ0.005
þ2+0.002 +0.001 0 þ0.001 þ0.002 þ0.003 þ0.004 þ0.005 þ0.006
þ3+0.001 0 þ0.001 þ0.002 þ0.003 þ0.004 þ0.005 þ0.006 þ0.007
þ40 þ0.001 þ0.002 þ0.003 þ0.004 þ0.005 þ0.006 þ0.007 þ0.008
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. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6736 and rear pinion bearing onto Screw 6741
(Fig. 6).(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 6).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
Fig. 5 Adjustment Shim Loactions
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
BR/BEFRONT AXLE - 248FBI 3 - 51
FRONT AXLE - 248FBI (Continued)

NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Place Scooter Block/Dial Indicator in position
in the housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 6). Hold scooter block in place and
zero the dial indicator face to the pointer. Tighten
dial indicator face lock screw.
(8) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
(9) 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. 9). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(10) Select a shim/oil baffle equal to the dial indi-
cator reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 4). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
Fig. 6 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. 7 Pinion Height Block
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 8 Gauge Tools In Housing
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
3 - 52 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

(7) Using a dead-blow hammer, seat the differen-
tial dummy bearings to each side of the housing (Fig.
12) and (Fig. 13).
(8) Thread Pilot Stud C-3288-B into rear cover bolt
hole below ring gear (Fig. 14).
(9) Attach the Dial Indicator C-3339 to pilot stud.
Position the dial indicator plunger on a flat surface
between the ring gear bolt heads (Fig. 14).
(10) Push and hold differential case to pinion gear
side of the housing and zero dial indicator (Fig. 15).(11) Push and hold differential case to ring gear
side of the housing and record the dial indicator
reading (Fig. 16).
(12) Add 0.38 mm (0.015 in.) to the zero end play
total. This total represents the thickness of shims
Fig. 12 Seat Pinion Gear Side Dummy Bearing
1 - DEAD-BLOW HAMMER
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
Fig. 13 Seat Ring Gear Side Differential Dummy
Bearing
1 - DIFFERENTIAL HOUSING
2 - DEAD-BLOW HAMMER
3 - DIFFERENTIAL CASE
Fig. 14 Differential Side Play Measurement
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 Dial Indicator Location
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR ARM
4 - DIAL INDICATOR FACE
3 - 54 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)