2001 DODGE RAM Service Repair Manual

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Page 209 of 2889

DODGE RAM 2001 Service Repair Manual Fig. 51 Remove Pinion Gear
1 - RAWHIDE HAMMER
Fig. 52 Front Bearing Cup Removal
1 - REMOVER
2 - HANDLE
Fig. 53 Rear Bearing Cup Removal
1 - DRIVER
2 - HANDLE
Fig. 54 Collapsible Spacer
1 - COLLAPSIBLE

Page 210 of 2889

DODGE RAM 2001 Service Repair Manual (16) Remove the rear bearing from the pinion with
Puller/Press C±293-PA and Adapters C±293±37 (Fig.
55).
Place 4 adapter blocks so they do not damage
the bearing cage.
(17) Remove the pinion depth

Page 211 of 2889

DODGE RAM 2001 Service Repair Manual (4) Install new pinion seal with an appropriate
installer (Fig. 58).
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mes

Page 212 of 2889

DODGE RAM 2001 Service Repair Manual Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 62).
(12) Check bearing rotating torque with an inch
pound torque wrench (Fig. 62). Pinion rotating torque
sh

Page 213 of 2889

DODGE RAM 2001 Service Repair Manual REAR AXLE - 267RBI
TABLE OF CONTENTS
page page
REAR AXLE - 267RBI
DESCRIPTION..........................140
OPERATION............................140
DIAGNOSIS AND TESTING................142
AXLE.......

REAR AXLE - 267RBI
TABLE OF CONTENTS
page page
REAR AXLE - 267RBI
DESCRIPTION..........................140
OPERATION............................140
DIAGNOSIS AND TESTING................142
AXLE...............................142
REMOVAL.............................144
INSTALLATION..........................145
ADJUSTMENTS.........................145
SPECIFICATIONS........................153
SPECIAL TOOLS........................153
AXLE SHAFTS
REMOVAL.............................156
INSTALLATION..........................156
AXLE BEARINGS
REMOVAL.............................156
INSTALLATION..........................156
PINION SEAL
REMOVAL.............................156INSTALLATION..........................157
DIFFERENTIAL
REMOVAL.............................158
DISASSEMBLY..........................158
ASSEMBLY............................159
INSTALLATION..........................159
DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING................161
POWR-LOK .........................161
DISASSEMBLY..........................161
ASSEMBLY............................163
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................164
INSTALLATION..........................164
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................165
INSTALLATION..........................166
REAR AXLE - 267RBI
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 differential is
a one-piece design. The differential pinion mate shaft
is retained with a roll pin. Differential bearing pre-
load and ring gear backlash are adjusted by the use
of shims located between the differential bearing
cones and case. Pinion bearing preload is set and
maintained by the use of a solid shims.
Axles equipped with a Powr-Lokydifferential are
optional. A Powr-lokydifferential has a two-piece dif-
ferential case. A Powr-lokydifferential contains four
pinion gears and a two-piece pinion mate cross shaft
to provide increased torque to the non-slipping wheel
through a ramping motion in addition to the stan-
dard Trac-lokycomponents.
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
3 - 140 REAR AXLE - 267RBIBR/BE

Page 214 of 2889

DODGE RAM 2001 Service Repair Manual 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
occur

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
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). 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.
POWR-LOKYDIFFERENTIAL
The Powr-lokyclutches are engaged by two con-
current forces. The first being the preload force
exerted through Belleville spring washers within the
clutch packs. The second is the separating forces gen-
erated by the side gears as torque is applied through
the ring gear (Fig. 3).
The Powr-lokydesigns provide the differential
action needed for turning corners and for driving
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. The Powr-lokydifferential addition-
Fig. 1 Differential Operation - 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
Fig. 2 Differential Operation - On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 3 Powr-lokYLimited Slip Differential
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
BR/BEREAR AXLE - 267RBI 3 - 141
REAR AXLE - 267RBI (Continued)

Page 215 of 2889

DODGE RAM 2001 Service Repair Manual ally utilizes a ramping action supplied by the cross
shafts to increase the force applied to the clutch
packs to increase the torque supplied to the non-slip-
ping wheel. Powr-lokydifferentials resist

ally utilizes a ramping action supplied by the cross
shafts to increase the force applied to the clutch
packs to increase the torque supplied to the non-slip-
ping wheel. Powr-lokydifferentials resist wheel spin
on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, operation is
normal. In extreme cases of differences of traction,
the wheel with the least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, tooth
contact, worn/damaged gears, or the carrier housing
not having the proper offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion shaft can also cause a snap-
ping 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 a:
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 rearend vibra-
tion. Do not overlook engine accessories, brackets
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.
3 - 142 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

Page 216 of 2889

DODGE RAM 2001 Service Repair Manual DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tub

DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct
as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears and
bearings for further damage. Set
differential bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid
excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid
erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential
with the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential
with the correct fluid type and quantity.
3. Excessive spinning of one wheel/tire. 3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
BR/BEREAR AXLE - 267RBI 3 - 143
REAR AXLE - 267RBI (Continued)

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