2001 DODGE RAM brakes

AXLE SHAFTS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper and rotor. Refer to
Brakes for procedures.
(4) Remove ABS wheel speed sensor if equipped.
Refer to Brakes for procedures.
(5) Remove the cotter pin and axle hub nut.
(6) Remove hub bearing bolts (Fig. 22) and remove
hub bearing from the steering knuckle.
(7) Remove brake dust shield from knuckle.
(8) Remove axle shaft from the housing. Avoid
damaging the axle shaft oil seal.
INSTALLATION
(1) Clean axle shaft and apply a thin film of
Mopar Wheel Bearing Grease to the shaft splines,
seal contact surface, hub bore.
(2) Install axle shaft into the housing and differen-
tial side gears. Avoid damaging axle shaft oil seals in
the differential.
(3) Install dust shield and hub bearing on knuckle.
(4) Install hub bearing bolts and tighten to 170
N´m (125 ft. lbs.).
(5) Install axle washer and nut, tighten nut to 237
N´m (175 ft. lbs.). Align nut to next cotter pin hole
and install new cotter pin.
(6) Install ABS wheel speed sensor, brake rotor
and caliper. Refer to Brakes for proper procedures.
(7) Install wheel and tire assembly.
(8) Remove support and lower the vehicle.
AXLE SHAFTS -
INTERMEDIATE
REMOVAL
(1) Remove vacuum shift motor housing.
(2) Remove outer axle shaft.
(3) Remove inner axle shaft seal from shift motor
housing with a long drift or punch. Be careful not to
damage housing.
(4) Remove intermediate axle shaft and shift col-
lar.
(5) Remove intermediate axle shaft bearing (Fig.
23).
INSTALLATION
(1) Position bearing on the installation tool and
seat the bearing (Fig. 24) in the housing bore.
(2) Clean the inside perimeter of the axle shaft
tube with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(4) Install the inner axle seal (Fig. 25).
(5) Install shift collar in the axle housing.
(6) Lubricate the splined end of the intermediate
axle shaft with multi-purpose lubricant.
(7) Insert the intermediate axle shaft into the dif-
ferential side gear.
CAUTION: Apply all-purpose lubricant to the axle
shaft splines to prevent damage to the seal during
axle shaft installation.
Fig. 22 Hub and Knuckle
1 - KNUCKLE
2 - HUB BEARING
Fig. 23 Bearing Removal
1 - BEARING
2 - SHIFT MOTOR HOUSING OPENING
3 - AXLE TUBE
4 - LOCATION FOR OPEN-END WRENCH
5 - SPECIAL TOOL 5041-2
6 - NUT
7 - SPECIAL TOOL 5041-3
8 - SPECIAL TOOL D-354-2
3 - 28 FRONT AXLE - 216FBIBR/BE

(5) Position yoke with the sockets in a vise (Fig.
31).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake calipers and rotors, Refer to
Brakes for procedure.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove propeller shaft from the yoke.
(6) Rotate pinion gear three or four times and ver-
ify it rotates smoothly.
(7) Record rotating torque of the pinion gear with
an inch pound torque wrench for installation refer-
ence.
(8) Remove pinion yoke nut and washer with
Remover C-452 and Flange Wrench C-3281 (Fig. 32).
(9) Remove pinion shaft seal with a pry tool or
slide hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 33).
(2) Install yoke on the pinion gear with Installer
W-162-D (Fig. 34).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining
nut. Damage to collapsible spacer or bearings may
result.
Fig. 30 Axle Shaft U-Joint
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 31 Yoke Bearing Cap
1 - LARGE-DIAMETER SOCKET WRENCH
2 - VISE
3 - SMALL-DIAMETER SOCKET WRENCH
3 - 34 FRONT AXLE - 216FBIBR/BE
SINGLE CARDAN UNIVERSAL JOINTS (Continued)

(3) Install anewnut on the pinion gear. Tighten
the nut only enough to remove the shaft end play.
(4) Rotate the pinion shaft using a inch pound
torque wrench. Rotating torque should be equal to
the reading recorded during removal, plus an addi-
tional 0.56 N´m (5 in. lbs.) (Fig. 35).
(5) If the rotating torque is to low, use Holder
6719A to hold the pinion yoke (Fig. 36) and tighten
the pinion shaft nut in 6.8 N´m (5 ft. lbs.) until
proper rotating torque is achieved.
(6) Installation propeller shaft with reference
marks aligned.
(7) Check and add gear lubricant to axle if neces-
sary.(8) Install brake rotors and calipers, refer to
Brakes for procedure.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.
Fig. 32 Pinion Yoke
1 - YOKE HOLDER
2 - YOKE
3 - YOKE PULLER
Fig. 33 Pinion Seal Installer
1 - HANDLE
2 - INSTALLER
Fig. 34 Pinion Yoke Installer
1 - PINION FLANGE
2 - DIFFERENTIAL HOUSING
Fig. 35 Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
BR/BEFRONT AXLE - 216FBI 3 - 35
PINION SEAL (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)

AXLE SHAFTS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper and rotor. Refer to
Brakes for procedures.
(4) Remove ABS wheel speed sensor if equipped.
Refer to Brakes for procedures.
(5) Remove the cotter pin and axle hub nut.
(6) Remove hub bearing bolts (Fig. 22) and remove
hub bearing from the steering knuckle.
(7) Remove brake dust shield from knuckle.(8) Remove axle shaft from the housing. Avoid
damaging the axle shaft oil seal.
INSTALLATION
(1) Clean axle shaft and apply a thin film of
Mopar Wheel Bearing Grease to the shaft splines,
seal contact surface, hub bore.
(2) Install axle shaft into the housing and differen-
tial side gears. Avoid damaging axle shaft oil seals in
the differential.
(3) Install dust shield and hub bearing on knuckle.
(4) Install hub bearing bolts and tighten to 170
N´m (125 ft. lbs.).
(5) Install axle washer and nut, tighten nut to 237
N´m (175 ft. lbs.). Align nut to next cotter pin hole
and install new cotter pin.
(6) Install ABS wheel speed sensor, brake rotor
and caliper. Refer to Brakes for proper procedures.
(7) Install wheel and tire assembly.
(8) Remove support and lower the vehicle.
AXLE SHAFTS -
INTERMEDIATE
REMOVAL - INTERMEDIATE AXLE
(1) Remove the vacuum shift motor housing.
(2) Remove the outer axle shaft.
(3) Remove the inner axle shaft seal from the shift
motor housing with a long drift or punch. Be careful
not to damage housing.
(4) Remove intermediate axle shaft and shift col-
lar.
(5) Remove the intermediate axle shaft bushing
(Fig. 23).
BLOCK, ADAPTER ± C-239-37
BLOCK, ADAPTER ± C-239-62
HOLDER, YOKE - 6719A
PINION DEPTH, SET ± 6730
Fig. 22 Hub and Knuckle
1 - KNUCKLE
2 - HUB BEARING
3 - 60 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

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) Raise the axle with lifting device and align to
the leaf spring centering bolts.
(2) Install the spring clamps and spring brackets.
Refer to 2 Suspension for procedures.
(3) Install shock absorbers and tighten nuts to 82
N´m (60 ft. lbs.).
(4) Install the RWAL sensor to the differential
housing, if necessary. Refer to 5 Brakes for proce-
dures.
(5) Connect the parking brake cables and cable
brackets.
(6) Install the brake drums. Refer to 5 Brakes for
procedures.
(7) Connect the brake hose to the axle junction
block. Refer to 5 Brakes for procedures.
(8) Install axle vent hose.
(9) Align propeller shaft and pinion companion
flange reference marks. Install the companion flange
bolts. Tighten to 108 N´m (80 ft. lbs.).
(10) Install the wheels and tires.
(11) Add gear lubricant, if necessary. Refer to
Specifications for lubricant requirements.
(12) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets
only. The identifying numbers for the ring gear and
pinion are painted onto the pinion gear head (Fig. 6)
and the side of the ring gear. A plus (+) number,
minus (±) number or zero (0) along with the gear set
sequence number (01 to 99) is on each gear. This first
number is the amount (in thousandths of an inch)
the depth varies from the standard depth setting of a
pinion marked with a (0). The next two numbers are
the sequence number of the gear set. The standard
depth provides the best teeth contact pattern. Refer
to Backlash and Contact Pattern for additional infor-
mation.
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
behind the rear pinion bearing. (Fig. 7).
If a new gear set is being installed, note the depth
variance painted onto both the original and replace-
ment pinion. Add or subtract the thickness of the
original depth shims to compensate for the difference
in the depth variances. Refer to the Depth Variance
chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.Note the painted number on the shaft of the drive
pinion (±1, ±2, 0, +1, +2, etc.). The numbers repre-
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 number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 6 Pinion ID Number
1 - PRODUCTION NUMBER
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 7 Adjustment Shim Locations
1 - AXLE HOUSING
2 - COLLAPSIBLE SPACER
3 - PINION BEARING
4 - PINION DEPTH SHIM
5 - DRIVE PINION GEAR
6 - BEARING CUP
3 - 84 REAR AXLE-91/4BR/BE
REAR AXLE - 9 1/4 (Continued)

AXLE SHAFTS
REMOVAL
(1) Place the transmission in NEUTRAL and raise
and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake drum (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DRUM - REMOVAL) ..
(4) Clean all foreign material from housing cover
area.
(5) Remove the housing cover and drain lubricant.
(6) Rotate differential case to access the pinion
shaft lock screw. Remove lock screw and pinion shaft
from differential case (Fig. 17).
(7) Push axle shaft inward then remove axle shaft
C-lock (Fig. 18).
(8) Remove axle shaft being carefull not to damage
shaft bearing and seal.
(9) Inspect axle shaft seal for leakage or damage.
(10) Inspect axle shaft bearing contact surface for
signs of brinelling, galling and pitting.
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing and
engage it into side gear splines.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) Insert C-lock in end of axle shaft. Push axle
shaft outward to seat C-lock in side gear.
(3) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctiteton the
threads. Tighten lock screw to 11 N´m (8 ft. lbs.).
Trac-lok Tools 8139
Height Block 8542
Arbor Discs 8541
Fig. 17 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION MATE SHAFT
Fig. 18 Axle Shaft C-Lock
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
BR/BEREAR AXLE - 9 1/4 3 - 93
REAR AXLE - 9 1/4 (Continued)