2001 DODGE RAM bolt pattern

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)

DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind the
differential side bearing cones. The proper shim
thickness can be determined using slip-fit Dummy
Bearings D-345 in place of the differential side bear-
ings and a Dial Indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 10). Differential shim measurements
are performed with spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove differential side bearings from differ-
ential case.(2) Remove factory installed shims from differen-
tial case.
(3) Install ring gear on differential case and
tighten bolts to specification.
(4) Install dummy side bearings D-345 on differen-
tial case.
(5) Install differential case in the housing.
(6) Install the marked bearing caps in their correct
positions and snug the bolts (Fig. 11).
Fig. 9 Pinion Gear Depth Measurement
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 Adjustment Shim Loactions
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
Fig. 11 Bearing Cap Bolts
1 - BEARING CAP
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
3 - 20 FRONT AXLE - 216FBIBR/BE
FRONT AXLE - 216FBI (Continued)

(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 19).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(34) Zero dial indicator face to pointer.
(35) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the housing to the other (Fig.
20).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform
Gear Contact Pattern Analysis procedure.
GEAR CONTACT PATTERN
The ring and pinion gear contact patterns will
show if the pinion depth is correct. It will also show
if the ring gear backlash has been adjusted correctly.
The backlash can be adjusted within specifications to
achieve desired tooth contact patterns.
(1) Apply a thin coat of hydrated ferric oxide or
equivalent to the drive and coast side of the ring gear
teeth.
(2) Wrap, twist and hold a shop towel around the
pinion yoke to increase the turning resistance of the
pinion. This will provide a more distinct contact pat-
tern.
(3) With a boxed end wrench on the ring gear bolt,
rotate the differential case one complete revolution in
both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
21)and adjust pinion depth and gear backlash as nec-
essary.
Fig. 19 Ring Gear Backlash Measurement
1 - DIAL INDICATOR
Fig. 20 Backlash Shim
BR/BEFRONT AXLE - 216FBI 3 - 23
FRONT AXLE - 216FBI (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 - 38 FRONT AXLE - 216FBIBR/BE
DIFFERENTIAL (Continued)

(11) Install yoke washer and anewnut on the
pinion gear. Tighten the nut to 258 N´m (190 ft. lbs.)
minimum.Do not over-tighten.Maximum torque is
393 N´m (290 ft. lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion gear bearing preload torque and never
exceed specified preload torque. If preload torque
is exceeded a new collapsible spacer must be
installed.
(12) Use Yoke Holder 6719A to hold the yoke (Fig.
61) and tighten the nut in 6.8 N´m (5 ft. lbs.) until
the rotating torque is achieved. Measure the preload
torque frequently to avoid over-tightening the nut.
(13) Check bearing preload torque with an inch
pound torque wrench (Fig. 62). The torque necessary
to rotate the pinion gear should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2 to 5 N´m (15 to 35 in. lbs.).
(14) Invert differential case in a vise and start two
ring gear bolts. This will provide case-to-ring gear
bolt hole alignment.
(15) Installnewring gear bolts and alternately
tighten to 108 N´m (80 ft. lbs.). (Fig. 63).
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(16) Install differential in axle housing and verify
gear mesh and contact pattern. Refer to Adjustments
(Gear Contact Pattern).
(17) Install differential cover and fill with lubri-
cant.(18) Install propeller shaft with reference marks
aligned.
(19) Remove support and lower vehicle.
Fig. 61 Tightening Pinion Nut
1 - PINION FLANGE
2 - YOKE HOLDING
3 - DIFFERENTIAL HOUSING
Fig. 62 Pinion Rotating Torque
1 - PINION YOKE
2 - INCH POUND TORQUE WRENCH
Fig. 63 Ring Gear Bolt
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 44 FRONT AXLE - 216FBIBR/BE
PINION GEAR/RING GEAR (Continued)

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.
BR/BEFRONT AXLE - 248FBI 3 - 49
FRONT AXLE - 248FBI (Continued)

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.
(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 127 mm (5.00 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).
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.
3 - 50 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)