2001 DODGE RAM Service Repair Manual

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Page 169 of 2889

DODGE RAM 2001 Service Repair Manual 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.(1

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)

Page 170 of 2889

DODGE RAM 2001 Service Repair Manual DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 27).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove the
differential pinions and thrust washers (Fig. 28).(4) Remove the di

Page 171 of 2889

DODGE RAM 2001 Service Repair Manual 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 hol

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)

Page 172 of 2889

DODGE RAM 2001 Service Repair Manual (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 stud

Page 173 of 2889

DODGE RAM 2001 Service Repair Manual (7) Position a small screw driver in slot of
Threaded Adapter Disc C-6960-3 (Fig. 35) to prevent
adapter from turning.
(8) Install Forcing Screw C-6960-4 and tighten
screw to 122 N´m (90 ft. lbs.) ma

Page 174 of 2889

DODGE RAM 2001 Service Repair Manual ASSEMBLY
Clean all components in cleaning solvent. Dry com-
ponents with compressed air. Inspect clutch pack
plates for wear, scoring or damage. Replace both
clutch packs if any one component in eithe

Page 175 of 2889

DODGE RAM 2001 Service Repair Manual (10) Rotate case with Turning Bar C-6960-2 until
the pinion shaft holes in pinion gears align with
holes in case. It may be necessary to slightly tighten
the forcing screw in order to install the pini

Page 176 of 2889

DODGE RAM 2001 Service Repair Manual DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove bearings from the differential case
with Puller C-293-PA, Adapters C-293-47 and Plug
SP-293-3 (Fig. 43).
I

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