2001 DODGE RAM wheel

(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)

SPECIFICATIONS
FRONT AXLE - 216FBI
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.55, 3.92, 4.10
Ring Gear Diameter 216 mm (8.50 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 109.5 mm (4.312 in.)
Pinion Bearing Preload - Original Bearing 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearing 2-4 N´m (15-35 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug Fill Hole 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Pinion Nut 258-393 190-290 -
Ring Gear Bolts 108 80 -
Shift Motor Bolts 11 8 -
Axle Nut 237 175 -
Wheel Bearing Bolts 170 125 -
SPECIAL TOOLS
FRONT AXLES
REMOVER - C-452
INSTALLER - 8108
SPREADER - W-129-B
INSTALLER - C-3095-A
BR/BEFRONT AXLE - 216FBI 3 - 25
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

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. When
this 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. 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 - 30 FRONT AXLE - 216FBIBR/BE
AXLE VACUUM MOTOR (Continued)

(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)

FRONT AXLE - 248FBI
TABLE OF CONTENTS
page page
FRONT AXLE - 248FBI
DESCRIPTION...........................45
OPERATION.............................45
DIAGNOSIS AND TESTING.................46
AXLE................................46
REMOVAL..............................50
INSTALLATION...........................50
ADJUSTMENTS..........................50
SPECIFICATIONS........................58
SPECIAL TOOLS.........................58
AXLE SHAFTS
REMOVAL..............................60
INSTALLATION...........................60
AXLE SHAFTS - INTERMEDIATE
REMOVAL..............................60
INSTALLATION...........................61
AXLE SHAFT SEALS
REMOVAL..............................61
INSTALLATION...........................61
AXLE VACUUM MOTOR
DESCRIPTION...........................62
OPERATION.............................62
DIAGNOSIS AND TESTING.................63VACUUM MOTOR.......................63
REMOVAL..............................65
DISASSEMBLY...........................65
ASSEMBLY.............................65
INSTALLATION...........................65
SINGLE CARDAN UNIVERSAL JOINTS
REMOVAL..............................65
INSTALLATION...........................66
PINION SEAL
REMOVAL..............................66
INSTALLATION...........................66
DIFFERENTIAL
REMOVAL..............................68
DISASSEMBLY...........................68
ASSEMBLY.............................69
INSTALLATION...........................69
DIFFERENTIAL CASE BEARINGS
REMOVAL..............................71
INSTALLATION...........................71
PINION GEAR/RING GEAR
REMOVAL..............................72
INSTALLATION...........................74
FRONT AXLE - 248FBI
DESCRIPTION
The housing for the 248 Front Beam-design Iron
(FBI) axle 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 248 FBI 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
BR/BEFRONT AXLE - 248FBI 3 - 45

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. 2).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.
3). 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.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, 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-
Fig. 1 248 FBI Differential Cover
1 - FILL PLUG
2 - MODEL NUMBER
3 - RATIO TAG
4 - DIFFERENTIAL COVER
Fig. 2 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. 3 Differential Operation-On Turns
1 - PINION GEARS ROTATE ON PINION SHAFT
3 - 46 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)