2001 DODGE RAM wheel bolt torque

Condition Possible Causes Correction
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.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears
and bearings for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure ring
gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he proper
specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Secure brake drums to the axle shaft.
(6) Remove the RWAL sensor from the differential
housing, if necessary. Refer to 5 Brakes for proce-
dures.
(7) Disconnect the brake hose at the axle junction
block. Do not disconnect the brake hydraulic lines at
the wheel cylinders. Refer to 5 Brakes for procedures.(8) Disconnect the parking brake cables and cable
brackets.
(9) Disconnect the vent hose from the axle shaft
tube.
(10) Mark the propeller shaft and companion
flange for installation alignment reference.
(11) Remove propeller shaft.
(12) Disconnect shock absorbers from axle.
(13) Remove the spring clamps and spring brack-
ets. Refer to 2 Suspension for procedures.
(14) Separate the axle from the vehicle.
BR/BEREAR AXLE - 9 1/4 3 - 83
REAR AXLE - 9 1/4 (Continued)

INSTALLATION
(1) Wipe the axle tube bore clean. Remove any old
sealer or burrs from the tube.
(2) Install the axle shaft bearing with Installer
C-4198 and Handle C-4171 . Ensure that the bearing
part number is against the installer. Verify that the
bearing in installed straight and the tool fully con-
tacts the axle tube when seating the bearing.
(3) Install anewaxle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark the universal joint, companion flange and
pinion shaft for installation reference.
(3) Remove the propeller shaft from the companion
flange. Secure the propeller shaft in an upright posi-
tion to prevent damage to the rear universal joint.
(4) Remove the wheel and tire assemblies.
(5) Remove the brake drums to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate the companion flange three or four
times.
(7) Measure the amount of torque necessary to
rotate the pinion with an inch pound torque wrench.
Record the torque reading for installation reference.
(8) Install socket head bolts into two of the
threaded holes in the companion flange, 180É apart.
(9) Position Holder 6719A against the companion
flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the
bolts so the holder is held to the flange.
(10) Hold the flange with holder and remove the
pinion nut and washer.
(11) Remove the companion flange with Remover
C-452 (Fig. 22).
(12) Remove pinion seal with a pry tool or slide-
hammer mounted screw.
INSTALLATION
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with Installer C-3860-A
and Handle C-4171.NOTE: The seal is correctly installed when the seal
flange contacts the face of the differential housing.
(3) Position the companion flange on the end of the
shaft with the reference marks aligned.
(4) Install socket head bolts into two of the
threaded holes in the companion flange, 180É apart.
(5) Position Holder 6719A against the companion
flange and install a hex head bolt and washer into
one of the remaining threaded holes. Tighten the
bolts so the holder is held to the flange.
(6) Seat companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Remove the installer and install the pinion
washer and anewpinion nut. The convex side of the
washer must face outward.
CAUTION: Do not exceed the minimum tightening
torque when installing the companion flange retain-
ing nut at this point. Damage to collapsible spacer
or bearings may result.
(8) Hold companion flange with Holder 6719 and
tighten the pinion nut to 285 N´m (210 ft. lbs.) (Fig.
23). Rotate pinion several revolutions to ensure the
bearing rollers are seated.
(9) Rotate the pinion using an (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N´m (5 in. lbs.) (Fig. 24).
Fig. 22 Companion Flange Remover
1 - COMPANION FLANGE
2 - PULLER TOOL
BR/BEREAR AXLE - 9 1/4 3 - 95
AXLE BEARINGS (Continued)

CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.(10) If the rotating torque is low, use Holder 6719
to hold the companion flange (Fig. 23) and tighten
the pinion nut in 6.8 N´m (5 ft. lbs.) increments until
proper rotating torque is achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(11) The seal replacement is unacceptable if the
final pinion nut torque is less than 285 N´m (210 ft.
lbs.).
(12) Install the propeller shaft with the installa-
tion reference marks aligned.
(13) Tighten the companion flange bolts to 108
N´m (80 ft. lbs.).
(14) Install the brake drums.
(15) Install wheel and tire assemblies and lower
the vehicle.
(16) Check the differential housing lubricant level.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential housing cover.
(3) Remove differential housing cover and drain
the lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the axle shafts.
(6) Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(7) Mark the differential housing and differential
bearing caps for installation reference (Fig. 25).
(8) Remove bearing threaded adjuster lock from
each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
(9) Loosen the threaded adjusters with Wrench
C-4164 (Fig. 26).
(10) Hold the differential case while removing
bearing caps and adjusters.
(11) Remove the differential case.
NOTE: Each differential bearing cup and threaded
adjuster must be kept with their respective bearing.
Fig. 23 Pinion Nut
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
Fig. 24 Pinion Rotation Torque
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
3 - 96 REAR AXLE-91/4BR/BE
PINION SEAL (Continued)

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. Carefully position the assem-
bled differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations
(Fig. 29).
(3) 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.
(4) 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.
(5) Install the axle shafts.
(6) Apply a bead of Mopar Silicone Rubber Sealant
or equivalent to the housing cover (Fig. 30).Install the housing cover within 5 minutes
after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 N´m (30 ft. lbs.) torque.
(8) Fill differential with lubricant to bottom of the
fill plug hole. Refer to the Lubricant Specifications
for the quantity and type.
(9) Install the fill hole plug and lower the vehicle.
(10) Trac-lokydifferential equipped vehicles
should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKY
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lokyunit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-loky
Lubricant (friction modifier) should be added after
repair service 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.
Fig. 29 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - ADJUSTER LOCK
4 - BEARING CAP
Fig. 30 Differential Cover
1 - SEALANT
2 - DIFFERENTIAL COVER
3 - 98 REAR AXLE-91/4BR/BE
DIFFERENTIAL (Continued)

(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. 31).
(6) If rotating torque is less than 22 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 side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 32).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-lokydifferential can be serviced
with the ring gear installed.
(3) Remove pinion shaft roll pin.
(4) Remove pinion shaft with a drift and hammer
(Fig. 33).
(5) Install and lubricate Step Plate C-6960-3 (Fig.
34).
(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. 31 Trac-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 32 Differential Case Holding Fixture
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 33 Pinion Shaft
1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR
BR/BEREAR AXLE - 9 1/4 3 - 99
DIFFERENTIAL - TRAC-LOK (Continued)

(19) Position ring gear on the differential case and
start two ring gear bolts. This will provide case-to-
ring gear bolt hole alignment.
(20) Invert the differential case in the vise.
(21) Installnewring gear bolts and alternately
tighten to 156 N´m (115 ft. lbs.) (Fig. 59).
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(22) Install differential in axle housing and verify
gear mesh and contact pattern.(23) Install axle shafts.
(24) Install wheel and tire assemblies.
(25) Install differential cover and fill with gear
lubricant.
(26) Install propeller shaft wtih reference marks
aligned.
(27) Remove support and lower vehicle.
Fig. 58 Pinion
1 - COMPANION FLANGE
2 - TORQUE WRENCHFig. 59 Ring Gear Bolts
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
4 - DIFFERENTIAL CASE
3 - 108 REAR AXLE-91/4BR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)

REAR AXLE - 248RBI
TABLE OF CONTENTS
page page
REAR AXLE - 248RBI
DESCRIPTION..........................109
OPERATION............................109
DIAGNOSIS AND TESTING.................111
AXLE...............................111
REMOVAL.............................113
INSTALLATION..........................114
ADJUSTMENTS.........................114
SPECIFICATIONS........................122
SPECIAL TOOLS........................122
AXLE SHAFTS
REMOVAL.............................125
INSTALLATION..........................125
AXLE BEARINGS
REMOVAL.............................125
INSTALLATION..........................125
PINION SEAL
REMOVAL.............................125INSTALLATION..........................125
DIFFERENTIAL
REMOVAL.............................127
DISASSEMBLY..........................128
ASSEMBLY............................128
INSTALLATION..........................129
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING................130
TRAC-LOK...........................130
DISASSEMBLY..........................130
ASSEMBLY............................132
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................134
INSTALLATION..........................134
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................135
INSTALLATION..........................137
REAR AXLE - 248RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housings
consist of an iron center casting (differential housing)
with axle shaft tubes extending from either side. The
tubes are pressed in to form a one-piece axle housing.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axles are equipped with full-floating axle
shafts, meaning that loads are supported by the axle
housing tubes. The full-float axle shafts are retained
by bolts attached to the hub. The hub rides on two
bearings at the outboard end of the axle tube. The
axle shafts can be removed without disturbing or
removing the wheel bearings. The wheel bearings are
opposed tapered roller bearings and are contained in
the hub assembly.
The removable, stamped steel cover provides a
means for inspection and service without removing
the complete axle from the vehicle. A small, stamped
metal axle gear ratio identification tag is attached to
the housing cover via one of the cover bolts. This tag
also identifies the number of ring and pinion teeth.
The rear wheel anti-lock (RWAL) brake speed sen-
sor is attached to the top, forward exterior of the dif-
ferential housing. A seal is located between the
sensor and the wire harness connector. The seal mustbe in place when the wire connector is connected to
the sensor. The RWAL brake exciter ring is press-fit-
ted onto the differential case against the ring gear
flange.
The differential case for the standard differentials
and the Trac-lokydifferential are a one-piece design.
The differential pinion mate shaft is retained with a
roll pin. Differential bearing preload and ring gear
backlash are adjusted by the use of shims located
between the differential bearing cones and case. Pin-
ion bearing preload is set and maintained by the use
of a solid shims.
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear 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.
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
BR/BEREAR AXLE - 248RBI 3 - 109

Condition Possible Causes Correction
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.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears
and bearings for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure ring
gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he proper
specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position a suitable lifting device under the
axle.
(3) Secure axle to device.
(4) Remove the wheels and tires.
(5) Secure brake drums to the axle shaft.
(6) Remove RWAL sensor from the differential
housing, if necessary. Refer to 5 Brakes for proce-
dures.
(7) Disconnect the brake hose at the axle junction
block. Do not disconnect the brake hydraulic lines at
the wheel cylinders. Refer to 5 Brakes for procedures.(8) Disconnect the parking brake cables and cable
brackets.
(9) Disconnect the vent hose from the axle shaft
tube.
(10) Mark propeller shaft and yoke for installation
alignment reference.
(11) Remove propeller shaft.
(12) Disconnect shock absorbers from axle.
(13) Remove spring clamps and spring brackets.
Refer to 2 Suspension for procedures.
(14) Separate axle from the vehicle.
BR/BEREAR AXLE - 248RBI 3 - 113
REAR AXLE - 248RBI (Continued)