2001 DODGE RAM brake

(8) Install a new cotter pin in hub nut. Tighten the
nut as needed to align cotter pin hole in shaft with
the opening in the nut.
(9) Install the rotor, brake caliper with adapter,
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
DISC BRAKE CALIPERS - INSTALLATION).
(10) Install the ABS wheel speed sensor if
equipped, (Refer to 5 - BRAKES/ELECTRICAL/
FRONT WHEEL SPEED SENSOR - INSTALLA-
TION).
(11) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(12) Remove the support and lower the vehicle.
(13) Apply the brakes several times to seat the
brake shoes and the caliper piston. Do not move the
vehicle until a firm brake pedal is obtained.
KNUCKLE
DESCRIPTION
The knuckles are a single casting with legs
machined for the upper and lower ball joints. The
knuckles also has machined mounting locations for
the front brake calipers adapters and hub bearing
assembly.
OPERATION
The steering knuckles pivots between the upper
and lower ball joints. The steering linkage is
attached to the knuckles controls vehicle steering.
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen. Remove knuckle from axle tube yokes.
REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Remove tie-rod or drag link end from the steer-
ing knuckle arm.
(3) Remove the ABS sensor wire and bracket from
knuckle. Refer to Brakes, for proper procedures.
(4) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen.
(6) Remove knuckle from axle tube yokes.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 108
N´m (80 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(3) Install and tighten upper ball stud nut to 101
N´m (75 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Install the hub bearing and axle shaft.
(5) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(6) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedures.
INSTALLATION
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 47
N´m (35 ft. lbs.) torque. Do not install cotter pin at
this time.
(3) Install and tighten upper ball stud nut to 94
N´m (70 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Retorque lower ball stud nut to 190±217 N´m
(140±160 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(5) Install the hub bearing and axle shaft.
(6) Install tie-rod or drag link end onto the steer-
ing knuckle arm.
(7) Install the ABS sensor wire and bracket to the
knuckle. Refer to Brakes, for proper procedure.
LOWER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Paint or scribe alignment marks on the cam
adjusters and suspension arm for installation refer-
ence (Fig. 15).
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
22).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut.
(3) Install the cam bolt, cam and nut in the axle
and align the reference marks.
(4) Remove support and lower the vehicle.
(5) Tighten cam nut at the axle bracket to 190
N´m (140 ft. lbs.). Tighten rear nut at the frame
bracket to 190 N´m (140 ft. lbs.).
2 - 20 FRONT - 4WDBR/BE
HUB / BEARING (Continued)

Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.
DIAGNOSIS AND TESTING - PROPELLER
SHAFT
VIBRATION
Tires that are out-of-round, or wheels that are
unbalanced, will cause a low frequency vibration.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
Brake drums that are unbalanced will cause a
harsh, low frequency vibration. (Refer to 5 - BRAKES
- DIAGNOSIS AND TESTING)
Driveline vibration can also result from loose or
damaged engine mounts.
Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
specific speed range is not usually caused by a pro-
peller shaft being unbalanced. Defective universal
joints, or an incorrect propeller shaft angle, are usu-
ally the cause of such a vibration.
Fig. 3 Rear Propeller Shaft - Dana Axles
1 - SLIDING YOKE
2 - PROPELLER SHAFT
3 - PINION YOKE
4 - CLAMP
5 - SCREW
6 - OUTPUT SHAFT
Fig. 4 Rear Propeller Shaft - Corporate Axles
1 - COMPANION FLANGE
2 - COMPANION YOKE
3 - REAR PROPELLER SHAFT
Fig. 5 Propeller Shaft And Yoke
1 - REFERENCE MARKS
BR/BEPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)

DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
BALANCE
NOTE: Removing and re-indexing the propeller
shaft 180É relative to the yoke may eliminate some
vibrations.
If propeller shaft is suspected of being unbalanced,
it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas.If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor-
rectly aligned with the shaft.
(5) Check the universal joint clamp screws torque.
(6) Remove the wheels and tires. Install the wheel
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90É apart.(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 6).
(10) Start the engine and re-check for vibration. If
there is little or no change in vibration, move the
clamp to one of the other three positions. Repeat the
vibration test.
(11) If there is no difference in vibration at the
other positions, the source of the vibration may not
be propeller shaft.
(12) If the vibration decreased, install a second
clamp (Fig. 7) and repeat the test.
(13) If the additional clamp causes an additional
vibration, separate the clamps (1/2 inch above and
below the mark). Repeat the vibration test (Fig. 8).
(14) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
3 - 4 PROPELLER SHAFTBR/BE
PROPELLER SHAFT (Continued)

FRONT AXLE - 216FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 216FBI
DESCRIPTION...........................12
OPERATION.............................12
DIAGNOSIS AND TESTING.................13
AXLE................................13
REMOVAL..............................16
INSTALLATION...........................17
ADJUSTMENTS..........................17
SPECIFICATIONS........................25
SPECIAL TOOLS.........................25
AXLE SHAFTS
REMOVAL..............................28
INSTALLATION...........................28
AXLE SHAFTS - INTERMEDIATE
REMOVAL..............................28
INSTALLATION...........................28
AXLE SHAFT SEALS
REMOVAL..............................29
INSTALLATION...........................29
AXLE VACUUM MOTOR
DESCRIPTION...........................29
OPERATION.............................30
DIAGNOSIS AND TESTING.................31VACUUM MOTOR.......................31
REMOVAL..............................33
DISASSEMBLY...........................33
ASSEMBLY.............................33
INSTALLATION...........................33
SINGLE CARDAN UNIVERSAL JOINTS
REMOVAL..............................33
INSTALLATION...........................34
PINION SEAL
REMOVAL..............................34
INSTALLATION...........................34
DIFFERENTIAL
REMOVAL..............................36
DISASSEMBLY...........................36
ASSEMBLY.............................37
INSTALLATION...........................37
DIFFERENTIAL CASE BEARINGS
REMOVAL..............................39
INSTALLATION...........................39
PINION GEAR/RING GEAR
REMOVAL..............................40
INSTALLATION...........................42
FRONT AXLE - 216FBI
DESCRIPTION
The housing for the 216 Front Beam-design Iron
(FBI) axles consists of an iron center casting with
tubes on each side. The tubes are pressed into and
welded to the differential housing.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline
of the ring gear.
The axle has a vent used to relieve internal pres-
sure caused by lubricant vaporization and internal
expansion.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the
hub bearings. The hub bearings are bolted to the
steering knuckle at the outboard end of the axle tube
yoke. The hub bearings are serviced as an assembly.
The axles are equipped with ABS brake sensors.
The sensors are attached to the knuckle assemblies
and the tone rings are pressed onto the axle shaft.
Use care when removing axle shafts as NOT to
damage the tone wheel or the sensor.The stamped steel cover provides a means for
inspection and servicing the differential.
The 216 axle have the assembly part number and
gear ratio listed on a tag. The tag is attached to the
housing cover by one of the cover bolts. Build date
identification codes are stamped on the cover side of
a axle tube.
The differential case is a one-piece design. The dif-
ferential pinion mate shaft is retained with a roll
pin. Differential bearing preload and ring gear back-
lash is adjusted by the use of shims. The shims are
located between the differential bearing cones and
case. Pinion bearing preload is set and maintained by
the use of a collapsible spacer.
The axle differential covers can be used for identi-
fication of the axle (Fig. 1). A tag is also attached to
the cover.
OPERATION
The axle receives power from the transfer case
through the front propeller shaft. The front 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
3 - 12 FRONT AXLE - 216FBIBR/BE

Condition Possible Causes Correction
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.
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.
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) 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.
3 - 16 FRONT AXLE - 216FBIBR/BE
FRONT AXLE - 216FBI (Continued)

(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 109.5 mm (4.312 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).
Fig. 4 Pinion Gear ID Numbers
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
BR/BEFRONT AXLE - 216FBI 3 - 17
FRONT AXLE - 216FBI (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
(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)