2001 DODGE RAM engine

(10) Apply a bead of Mopar Silicone Rubber Seal-
ant or equivalent to the housing cover (Fig. 34).
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.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKY
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lokyunit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-loky
Lubricant (friction modifier) should be added after
repair service or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. Thiswill correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 35).
(6) If rotating torque is less than 22 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 36).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-lokydifferential can be serviced
with the ring gear installed.
(3) Remove pinion shaft roll pin.
(4) Remove pinion shaft with a drift and hammer
(Fig. 37).
(5) Install and lubricate Step Plate C-6960-3 (Fig.
38).
Fig. 34 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 35 Trac-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
3 - 130 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL (Continued)

REAR AXLE - 267RBI
TABLE OF CONTENTS
page page
REAR AXLE - 267RBI
DESCRIPTION..........................140
OPERATION............................140
DIAGNOSIS AND TESTING................142
AXLE...............................142
REMOVAL.............................144
INSTALLATION..........................145
ADJUSTMENTS.........................145
SPECIFICATIONS........................153
SPECIAL TOOLS........................153
AXLE SHAFTS
REMOVAL.............................156
INSTALLATION..........................156
AXLE BEARINGS
REMOVAL.............................156
INSTALLATION..........................156
PINION SEAL
REMOVAL.............................156INSTALLATION..........................157
DIFFERENTIAL
REMOVAL.............................158
DISASSEMBLY..........................158
ASSEMBLY............................159
INSTALLATION..........................159
DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING................161
POWR-LOK .........................161
DISASSEMBLY..........................161
ASSEMBLY............................163
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................164
INSTALLATION..........................164
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................165
INSTALLATION..........................166
REAR AXLE - 267RBI
DESCRIPTION
The Rear Beam-design Iron (RBI) axle housings
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 the
sensor and the wire harness connector. The seal mustbe 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 a solid shims.
Axles equipped with a Powr-Lokydifferential are
optional. A Powr-lokydifferential has a two-piece dif-
ferential case. A Powr-lokydifferential contains four
pinion gears and a two-piece pinion mate cross shaft
to provide increased torque to the non-slipping wheel
through a ramping motion in addition to the stan-
dard Trac-lokycomponents.
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
3 - 140 REAR AXLE - 267RBIBR/BE

ally utilizes a ramping action supplied by the cross
shafts to increase the force applied to the clutch
packs to increase the torque supplied to the non-slip-
ping wheel. Powr-lokydifferentials resist wheel spin
on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, operation is
normal. In extreme cases of differences of traction,
the wheel with the least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, 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-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
3 - 142 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(10) Install the propeller shaft with the installa-
tion reference marks aligned.
(11) Tighten the universal joint yoke clamp screws
to 19 N´m (14 ft. lbs.).
(12) Install the brake drums.
(13) Add gear lubricant to the differential housing,
if necessary. Refer to the Lubricant Specifications for
gear lubricant requirements.
(14) Install wheel and tire assemblies and lower
the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential 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 axle shafts.
(6) Note the orientation of the installation refer-
ence letters stamped on the bearing caps and hous-
ing machined sealing surface (Fig. 26).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 27).(9) Install the hold down clamps and tighten the
tool turnbuckle finger-tight.
(10) Install a Pilot Stud C-3288-B at the left side
of the differential housing. Attach dial indicator to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing (Fig. 27) and
zero the indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 27).
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. 28).
(14) Remove the case from housing. Tag bearing
cups to indicate their location.
DISASSEMBLY
(1) Remove roll-pin holding mate shaft in housing.
(2) Remove pinion gear mate shaft (Fig. 29).
(3) Rotate the differential side gears and remove
the pinion mate gears and thrust washers (Fig. 30).
(4) Remove the differential side gears and thrust
washers.Fig. 26 Bearing Cap Identification
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 27 Spread Differential Housing
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
3 - 158 REAR AXLE - 267RBIBR/BE
PINION SEAL (Continued)

DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING - POWR-LOKY
TEST
WARNING: WHEN SERVICING VEHICLES WITH A
POWER-LOKYDIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A POWER-LOKYAXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 35).
(6) If rotating torque is less than 22 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
The Powr-Lokydifferential has a two-piece cross
shaft and uses 2 disc and 3 plates for each clutch
pack. One plate and one disc in each clutch pack is
dished.
NOTE: Pay close attention to the clutch pack
arrangement during this procedure. Note the direc-
tion of the concave and convex side of the plates
and discs.
(1) Mark the ring gear half and cover half for
installation reference (Fig. 36).
(2) Remove the case attaching bolts and remove
the button cover half (Fig. 37).
(3) Remove top clutch pack (Fig. 38).
(4) Remove top side gear clutch ring.
(5) Remove top side gear.
(6) Remove pinion mate gears and cross shafts.
(7) Remove the same parts listed above from the
ring gear flange half of the case. Keep these parts
with the flange cover half for correct installation in
their original positions.
Fig. 34 Differential Cover
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
Fig. 35 Powr-lokYTest -Typical
1 - SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
BR/BEREAR AXLE - 267RBI 3 - 161
DIFFERENTIAL (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

on bumpy roads and provide more pulling power when
one wheel looses traction. Pulling power is provided
continuously until both wheels loose traction. If both
wheels slip due to unequal traction, Trac-lokyopera-
tion is normal. In extreme cases of differences of trac-
tion, the wheel with the least traction may spin.
DIAGNOSIS AND TESTING - AXLE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, incorrect pinion depth, 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-
cle turns. A worn pinion shaft can also cause a snap-
ping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changeswhen the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side±gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out-of-balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
BR/BEREAR AXLE - 286RBI 3 - 171
REAR AXLE - 286RBI (Continued)

DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential 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 axle shafts.
(6) Note the orientation of the installation refer-
ence letters stamped on the bearing caps and hous-
ing machined sealing surface (Fig. 26).
(7) Remove the differential bearing caps.
(8) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 27).
(9) Install the hold down clamps and tighten the
tool turnbuckle finger-tight.
(10) Install a Pilot Stud C-3288-B at the left side
of the differential housing. Attach dial indicator to
housing pilot stud. Load the indicator plunger
against the opposite side of the housing (Fig. 27) and
zero the indicator.
(11) Spread the housing enough to remove the case
from the housing. Measure the distance with the dial
indicator (Fig. 27).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. 28).
(14) Remove the case from housing. Tag bearing
cups to indicate their location.
Fig. 25 Check Pinion Rotation Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
Fig. 26 Bearing Cap Identification
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 27 Spread Differential Housing
1 - SPREADER
2 - DIAL INDICATOR
3 - DIFFERENTIAL
4 - DIFFERENTIAL HOUSING
5 - PILOT STUD
BR/BEREAR AXLE - 286RBI 3 - 187
PINION SEAL (Continued)