2001 DODGE RAM differential

INSTALLATION - INTERMEDIATE AXLE
(1) Position the bushing on installation tool and
seat the bushing (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 the 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.
(8) Insert the axle shaft into the tube. Engage the
splined end of the shaft with the shift collar.
(9) Install the vacuum shift motor housing.
AXLE SHAFT SEALS
REMOVAL
(1) Remove hub bearings and axle shafts.
(2) Remove axle shaft seal from the differential
housing with a long drift or punch.Be careful not
to damage housing.
(3) Clean the inside perimeter of the differential
housing with fine crocus cloth.
INSTALLATION
(1) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(2) Install the inner axle seal (Fig. 26).
(3) Install axles and hub bearings.
Fig. 23 Bushing Removal
1 - BUSHING
2 - SHIFT MOTOR HOUSING OPENING
3 - AXLE TUBE
4 - LOCATION FOR OPEN-END WRENCH
5 - SPECIAL TOOL 5041-2
6 - NUT
7 - SPECIAL TOOL 8417
8 - SPECIAL TOOL 8415
Fig. 24 Bushing Installation
1 - SHIFT MOTOR HOUSING OPENING
2 - SPECIAL TOOL 5417
3 - SPECIAL TOOL 5041-2
4 - SPECIAL TOOL 8416
5 - BUSHING
Fig. 25 Seal Installation
1 - SHIFT MOTOR HOUSING OPENING
2 - SEAL
3 - AXLE TUBE
4 - LOCATION FOR OPEN-END WRENCH
5 - SPECIAL TOOL 5041-2
6 - SPECIAL TOOL 8417
7 - SPECIAL TOOL 8411
BR/BEFRONT AXLE - 248FBI 3 - 61
AXLE SHAFTS - INTERMEDIATE (Continued)

AXLE VACUUM MOTOR
DESCRIPTION
The disconnect axle control system consists of:
²Shift motor.
²Indicator switch.
²Vacuum switch.
²Vacuum harness (Fig. 27).
OPERATION
The shift motor receives a vacuum signal from the
switch mounted on the transfer case when the vehi-
cle operator wants to switch from two wheel drive
mode to four wheel drive mode, or vice versa. Whenthis signal is received, the shift motor begins to move
the shift fork and collar within the axle housing. In
the four wheel drive mode, the shift collar connects
the axle intermediate shaft to the axle shaft to sup-
ply engine power to both front wheels. In two wheel
drive mode, the shift collar is disengaged from the
intermediate shaft and the intermediate shaft is
allowed to free-spin. When the two shafts are disen-
gaged, the load on the engine is reduced, thereby pro-
viding better fuel economy and road handling.
Fig. 26 Seal Installation
1 - DIFFERENTIAL HOUSING
2 - POSITION FOR OPEN-END WRENCH
3 - SPECIAL TOOL 5041-2
4 - SPECIAL TOOL 8417
5 - SEAL
6 - SPECIAL TOOL 8411
Fig. 27 Vacuum Control System
1 - CHECK VALVE
2 - CONTROL SWITCH ON TRANSFER CASE
3 - AIR VENT FILTER
4 - AXLE SHIFT MOTOR
5 - INDICATOR SWITCH
3 - 62 FRONT AXLE - 248FBIBR/BE
AXLE SHAFT SEALS (Continued)

REMOVAL
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove shift motor housing cover, gasket and
shield from the housing (Fig. 28).
DISASSEMBLY
(1) Remove E-clips from the shift motor housing
and shaft. Remove shift motor and shift fork from
the housing (Fig. 29).
(2) Remove O-ring seal from the shift motor shaft.
(3) Clean and inspect all components. Replaced
any component that is excessively worn or damaged.
ASSEMBLY
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert shift motor shaft through the hole in the
housing and shift fork. The shift fork offset should be
toward the differential.
(3) Install E-clips on the shift motor shaft and
housing.
INSTALLATION
(1) Install shift motor housing gasket and cover.
Ensure shift fork is correctly guided into the shift
collar groove.
(2) Install shift motor housing shield and tighten
the bolts to 11 N´m (96 in. lbs.).(3) Add 148 ml (5 ounces) of API grade GL 5
hypoid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(4) Install indicator switch, electrical connector
and vacuum harness.
SINGLE CARDAN UNIVERSAL
JOINTS
REMOVAL
Single cardan U-joint components are not service-
able. If defective they must be replaced as a unit.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 30).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket with an inside diameter is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
(4) Locate a socket with an outside diameter is
smaller than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap.
Fig. 28 Shift Motor Housing
1 - INDICATOR LAMP SWITCH
2 - DISCONNECT HOUSING
3 - VACUUM SHIFT MOTOR
4 - AXLE SHAFT
5 - SEAL
6 - SHIFT COLLAR
7 - SHIFT FORK
8 - BEARING
9 - INTERMEDIATE AXLE SHAFT
Fig. 29 Shift Motor Components
1 - INDICATOR SWITCH
2 - E-CLIP
3 - O-RING
4 - SHIFT MOTOR
5 - SHIFT FORK
6 - VACUUM PORTS
7 - DISCONNECT HOUSING AND GASKET
BR/BEFRONT AXLE - 248FBI 3 - 65
AXLE VACUUM MOTOR (Continued)

DIFFERENTIAL
REMOVAL
(1) Raise and support 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 hub bearings and axle shafts.
(6) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 37).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 38).
(9) Install the hold down clamps and tighten the
spreader turnbuckle finger-tight.
(10) Install Pilot Stud C-3288-B to the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 38) and zero the
dial indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 38).
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread it could be distorted or
damaged.
(12) Remove the dial indicator.(13) Pry the differential case loose from the hous-
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 39).
(14) Remove the case from housing.
(15) Remove and tag bearing cups to indicate their
original location.
DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 40).
Fig. 36 Tightening Pinion Shaft Nut
1 - PINION FLANGE
2 - HOLDING TOOL 6719
3 - AXLE HOUSING
Fig. 37 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 38 Spread Differential Housing
1 - HOUSING SPREADER W-129B
2 - DIAL INDICATOR C-3339
3 - DIFFERENTIAL
4 - AXLE HOUSING
5 - GUIDE PIN C-3288±B
3 - 68 FRONT AXLE - 248FBIBR/BE
PINION SEAL (Continued)

(3) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 41).
(4) Remove the differential side gears and thrust
washers.ASSEMBLY
(1) Install the differential side gears and thrust
washers.
(2) Install the pinion mate gears and thrust wash-
ers.
(3) Install the pinion gear mate shaft.
(4) Align the hole in the pinion gear mate shaft
with the hole in the differential case.
(5) Install and seat the pinion mate shaft roll-pin
in the differential case and mate shaft with a punch
and hammer (Fig. 42). Peen the edge of the roll-pin
hole in the differential case slightly in two places,
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing Preload and Gear
Backlash) procedures to determine proper shim
selection.
(1) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes. Install the hold
down clamps and tighten the tool turnbuckle finger-
tight.
Fig. 39 Differential Removal
1 - DIFFERENTIAL
2-PRYBAR
Fig. 40 Pinion Mate Shaft
1 - PINION MATE GEAR
2 - PINION MATE SHAFT
3 - SIDE GEAR
4 - DRIFT
Fig. 41 Pinion Mate/Side Gear
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
BR/BEFRONT AXLE - 248FBI 3 - 69
DIFFERENTIAL (Continued)

(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing and attach dial indicator to
the pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the dial indica-
tor.
(3) Spread the housing enough to install the case
in the housing. Measure the distance with the dial
indicator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove the dial indicator.
(5) Install differential into the housing. Tap the
differential case with a rawhide/rubber hammer to
ensure the bearings are seated in housing (Fig. 43).
(6) Remove the spreader.
(7) Install bearing caps in their original locations
(Fig. 44) and tighten bearing cap bolts to 109 N´m
(80 ft. lbs.).
(8) Install axle shafts.
(9) Install the hub bearings.
(10) Apply a bead of Mopar Silicone Rubber Seal-
ant or equivalent to the housing cover (Fig. 45).
Install the housing cover within 5 minutes
after applying the sealant.(11) Install the cover and any identification tag.
Tighten the cover bolts in a criss-cross pattern to 47
N´m (35 ft. lbs.).
(12) Refill the differential with Mopar Hypoid
Gear Lubricant or equivalent to bottom of the fill
plug hole. Refer to the Lubricant Specifications for
correct quantity and type.
(13) Install the fill hole plug and tighten to 34 N´m
(25 ft. lbs.).
(14) Remove support and lower vehicle.
Fig. 42 Pinion Mate Shaft Roll-Pin
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
Fig. 43 Differential Case
1 - RAWHIDE HAMMER
Fig. 44 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
3 - 70 FRONT AXLE - 248FBIBR/BE
DIFFERENTIAL (Continued)

DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove the bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-62, and
Step Plate C-4487-1 (Fig. 46).
INSTALLATION
(1) Using tool C-4190 with handle C-4171, install
differential side bearings (Fig. 47).
(2) Install differential case in axle housing.
Fig. 45 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 46 Differential Bearing Removal
1 - SPECIAL TOOL C-293-PA
2 - SPECIAL TOOL C-293-62
3 - SPECIAL TOOL C-4487-1
4 - BEARING
5 - DIFFERENTIAL
BR/BEFRONT AXLE - 248FBI 3 - 71
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the pinion gear.
(1) Raise and support the vehicle.
(2) Remove differential from housing.
(3) Place differential case in a vise with soft metal
jaw.
(4) Remove ring gear bolts from differential case.
(5) Drive ring gear from differential case with a
soft hammer (Fig. 48).
(6) Mark the pinion yoke and propeller shaft for
installation alignment.
(7) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(8) Hold pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(9) Remove pinion yoke with Puller C-452 and
Flange Wrench C-3281 (Fig. 49).
(10) Remove pinion gear from housing (Fig. 50).
(11) Remove pinion seal with a pry bar or screw
mounted slide hammer.(12) Remove oil slinger and front pinion bearing.
(13) Remove front pinion bearing cup with Driver
D-158 and Handle C-4171 (Fig. 51).
(14) Remove rear bearing cup with remover D-162
and Handle C-4171 (Fig. 52).
(15) Remove collapsible preload spacer (Fig. 53).
(16) Remove rear pinion bearing from pinion with
Puller C-293-PA and Adapters C-293-37 (Fig. 54).
(17) Remove pinion depth shims from the pinion
shaft and record thickness.
Fig. 47 Install Differential Side Bearings
1 - HANDLE C-4171
2 - DIFFERENTIAL CASE
3 - BEARING
4 - TOOL C-4190
Fig. 48 Ring Gear
1 - CASE
2 - RING GEAR
3 - HAMMER
Fig. 49 Pinion Yoke
1 - YOKE HOLDER
2 - YOKE
3 - YOKE PULLER
3 - 72 FRONT AXLE - 248FBIBR/BE
DIFFERENTIAL CASE BEARINGS (Continued)