2001 DODGE RAM sensor

INSTALLATION
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install 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 RWAL sensor to the differential hous-
ing, if necessary. Refer to 5 Brakes for procedures.
(5) Install parking brake cables, cable brackets
and brake drums. Refer to 5 Brakes for procedures.
(6) Connect brake hose to axle junction block.
Refer to 5 Brakes for procedures.
(7) Install axle vent hose.
(8) Align propeller shaft and pinion yoke reference
marks. Install universal joint straps and bolts.
Tighten to 19 N´m (14 ft. lbs.).
(9) Install the wheels and tires.
(10) Add gear lubricant, if necessary. Refer to
Lubricant Specifications for lubricant requirements.
(11) Remove lifting device from axle and lower the
vehicle.
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 136.53 mm (5.375 in.). The standard depth pro-
vides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern in this section for
additional 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.
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 number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 Adjustment Shim Loactions
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 267RBI 3 - 145
REAR AXLE - 267RBI (Continued)

REAR AXLE - 286RBI
TABLE OF CONTENTS
page page
REAR AXLE - 286RBI
DESCRIPTION..........................169
OPERATION............................169
DIAGNOSIS AND TESTING................171
AXLE...............................171
REMOVAL.............................173
INSTALLATION..........................174
ADJUSTMENTS.........................174
SPECIFICATIONS........................182
SPECIAL TOOLS........................182
AXLE SHAFTS
REMOVAL.............................185
INSTALLATION..........................185
AXLE BEARINGS
REMOVAL.............................185
INSTALLATION..........................185
PINION SEAL
REMOVAL.............................185INSTALLATION..........................185
DIFFERENTIAL
REMOVAL.............................187
DISASSEMBLY..........................188
ASSEMBLY............................188
INSTALLATION..........................188
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING................190
TRAC-LOK...........................190
DISASSEMBLY..........................190
ASSEMBLY............................190
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................192
INSTALLATION..........................192
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................193
INSTALLATION..........................195
REAR AXLE - 286RBI
DESCRIPTION
The 286 Rear Beam-design Iron (RBI) axle hous-
ings 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 thesensor and the wire harness connector. The seal must
be 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 solid shims.
Axles equipped with a Trac-Lokydifferential are
optional for the 286 RBI axle. A Trac-lokydifferen-
tial contains two clutch packs, four pinion gears, and
a one-piece pinion mate cross shaft to provide
increased torque to the non-slipping wheel in addi-
tion to the standard differential components. A Trac-
lokydifferential for the 286 RBI axle has a two-piece
differential case.
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
BR/BEREAR AXLE - 286RBI 3 - 169

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 - 286RBI 3 - 173
REAR AXLE - 286RBI (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 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 147.625 mm (5.812 in.). The standard depth pro-
vides the best teeth contact pattern. Refer to Back-
lash and Contact Pattern Analysis Paragraph in this
section for additional information.
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 5).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus amount needed.
Note the etched number on the face of the drive
pinion gear (±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 shim(s). If the num-
ber is positive, subtract that value from the thickness
of the depth shim(s). If the number is 0 no change is
necessary. Refer to the Pinion Gear Depth Variance
Chart.
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 5 Adjustment Shim Locations
1 - PINION BEARING PRELOAD SHIM
2 - DIFFERENTIAL BEARING SHIM
3 - PINION GEAR DEPTH SHIM
3 - 174 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM
GAS ENGINE
COOLING SYSTEM DIAGNOSISÐGASOLINE ENGINE
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE
GAUGE READS LOW1. Has a Diagnostic Trouble Code (DTC)
been set indicating a stuck open
thermostat?1. (Refer to 25 - EMISSIONS CONTROL -
DESCRIPTION) for On-Board Diagnostics
and DTC information. Replace thermostat
if necessary.
2. Is the temperature sending unit
connected?2. Check the temperature sensor
connector. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - SCHEMATIC -
ELECTRICAL) Repair connector if
necessary.
3. Is the temperature gauge operating
OK?3. Check gauge operation. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER/
ENGINE TEMPERATURE GAUGE -
DESCRIPTION) . Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks as
necessary. Refer to the Coolant section of
the manual text for WARNINGS and
CAUTIONS associated with removing the
radiator cap.
5. Improper operation of internal heater
doors or heater controls.5. Inspect heater and repair as necessary.
(Refer to 24 - HEATING & AIR
CONDITIONING - DIAGNOSIS AND
TESTING) for procedures.
TEMPERATURE
GAUGE READS HIGH
OR THE COOLANT
WARNING LAMP
ILLUMINATES.
COOLANT MAY OR
MAY NOT BE LOST OR
LEAKING FROM THE
COOLING SYSTEM1. Trailer is being towed, a steep hill is
being climbed, vehicle is operated in slow
moving traffic, or engine is being idled
with very high ambient (outside)
temperatures and the air conditioning is
on. Higher altitudes could aggravate
these conditions.1. This may be a temporary condition and
repair is not necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to the
normal range. If the gauge does not
return to the normal range, determine the
cause for overheating and repair. Refer to
Possible Causes (2-20).
2. Is the temperature gauge reading
correctly?2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL) . Repair as
necessary.
3. Is the temperature warning illuminating
unnecessarily?3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - SCHEMATIC -
ELECTRICAL).
4. Coolant low in coolant reserve/overflow
tank and radiator?4. Check for coolant leaks and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
BR/BECOOLING 7 - 7
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
16. Thermostat partially or completely
shut.16. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT
THERMOSTAT - REMOVAL) .
17. Viscous fan drive not operating
properly.17. Check fan drive operation and replace
as necessary. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL) .
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
19. Heater core leaking. 19. Check heater core for leaks. (Refer to
24 - HEATING & AIR CONDITIONING/
PLUMBING - DIAGNOSIS AND
TESTING). Repair as necessary.
TEMPERATURE
GAUGE READING IS
INCONSISTENT
(FLUCTUATES,
CYCLES OR IS
ERRATIC)1. During cold weather operation, with the
heater blower in the high position, the
gauge reading may drop slightly.1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine mounted
gauge sensor defective or shorted. Also,
corroded or loose wiring in this circuit.2. Check operation of gauge and repair if
necessary. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING).
3. Gauge reading rises when vehicle is
brought to a stop after heavy use (engine
still running)3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after re-starting a
warmed up (hot) engine.4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of
engine operation.
5. Coolant level low in radiator (air will
build up in the cooling system causing
the thermostat to open late).5. Check and correct coolant leaks. (Refer
to 7 - COOLING - DIAGNOSIS AND
TESTING).
6. Cylinder head gasket leaking allowing
exhaust gas to enter cooling system
causing a thermostat to open late.6. (a) Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
7. Water pump impeller loose on shaft. 7. Check water pump and replace as
necessary. (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
8. Loose accessory drive belt. (water
pump slipping)8. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND
TESTING). Check and correct as
necessary.
9. Air leak on the suction side of the
water pump allows air to build up in
cooling system causing thermostat to
open late.9. Locate leak and repair as necessary.
BR/BECOOLING 7 - 9
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) refill with correct
mixture (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Thermostat stuck shut. 7. Replace thermostat.
8. Bug screen or winter front being
used.8. Remove bug screen or winter
front.
9. Viscous fan drive not operating
properly.9. Check viscous fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
11. Heater core leaking. 11. Replace heater core.
12. cooling system hoses leaking. 12. Tighten clamps or Replace
hoses.
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)
TEMPERATURE GAUGE READING
INCONSISTENT ( ERRATIC,
CYCLES OR FLUCTUATES)1. Heavy duty cooling system,
extream cold ambient (outside)
temperature or heater blower motor
in high position.1. None. System operating normaly.
2. Temperature gauge or gauge
sensor defective.2. Check gauge. (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water
pump.6. Check for leak. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM
AND /OR COOLANT INTO
RESERVOIR BOTTLE.
(TEMPERATURE GAUGE MAY
READ HIGH)1. Radiator cap defective. 1. Replace radiator cap.
2. Radiator neck surface damaged. 2. Replace radiator.
BR/BECOOLING 7 - 13
COOLING (Continued)

ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION...........................40
OPERATION.............................40
COOLANT RECOVERY CONTAINER - 3.9L/5.2L/
5.9L/5.9L DIESEL
DESCRIPTION...........................41
OPERATION.............................41
REMOVAL..............................41
INSTALLATION...........................41
COOLANT RECOVERY CONTAINER - 8.0L
DESCRIPTION...........................42
OPERATION.............................42
RADIATOR FAN - 3.9L/5.2L/5.9L/8.0L
REMOVAL..............................42
CLEANING..............................43
INSPECTION............................43
INSTALLATION...........................43
RADIATOR FAN - 5.9L DIESEL
REMOVAL..............................44
CLEANING..............................44
INSPECTION............................44
INSTALLATION...........................45
ENGINE BLOCK HEATER - 3.9L/5.2L/5.9L
DESCRIPTION...........................45
OPERATION.............................45
REMOVAL..............................45
INSTALLATION...........................45
ENGINE BLOCK HEATER - 8.0L
DESCRIPTION...........................46
OPERATION.............................46
REMOVAL..............................46
INSTALLATION...........................46
ENGINE BLOCK HEATER - 5.9L DIESEL
DESCRIPTION...........................47
OPERATION.............................47
REMOVAL..............................47
INSTALLATION...........................47
ENGINE COOLANT TEMP SENSOR - 3.9L/5.2L/
5.9L
DESCRIPTION...........................48
OPERATION.............................48
REMOVAL..............................48
INSTALLATION...........................48
ENGINE COOLANT THERMOSTAT - 3.9L/5.2L/
5.9L
DESCRIPTION...........................49
OPERATION.............................49
DIAGNOSIS AND TESTING.................49
THERMOSTAT.........................49REMOVAL..............................49
INSTALLATION...........................50
ENGINE COOLANT THERMOSTAT - 8.0L
DESCRIPTION...........................52
OPERATION.............................52
DIAGNOSIS AND TESTING.................52
THERMOSTAT.........................52
REMOVAL..............................52
INSTALLATION...........................53
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL
DESCRIPTION...........................54
OPERATION.............................54
DIAGNOSIS AND TESTING.................54
THERMOSTAT.........................54
REMOVAL..............................55
INSTALLATION...........................55
FAN DRIVE VISCOUS CLUTCH - 3.9L/5.2L/5.9L/
8.0L
DESCRIPTION...........................56
OPERATION.............................56
DIAGNOSIS AND TESTING.................56
VISCOUS FAN DRIVE...................56
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL
DESCRIPTION...........................57
OPERATION.............................57
DIAGNOSIS AND TESTING.................58
VISCOUS FAN DRIVE...................58
RADIATOR - 3.9L/5.2L/5.9L
DESCRIPTION...........................59
OPERATION.............................59
DIAGNOSIS AND TESTING.................59
RADIATOR COOLANT FLOW..............59
REMOVAL..............................59
CLEANING..............................60
INSPECTION............................61
INSTALLATION...........................61
RADIATOR - 8.0L
DESCRIPTION...........................61
OPERATION.............................61
DIAGNOSIS AND TESTING.................61
RADIATOR COOLANT FLOW..............61
REMOVAL..............................62
CLEANING..............................62
INSPECTION............................62
INSTALLATION...........................63
RADIATOR - 5.9L DIESEL
DESCRIPTION...........................63
OPERATION.............................63
BR/BEENGINE 7 - 39