2002 DODGE RAM brake

SPECIAL TOOLS
LINK/COIL SUSPENSION
HUB / BEARING
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the hub extension mounting nuts and
remove the extension from the rotor if equipped (Fig.
2).(4) Remove the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(5) Remove the cotter pin and the hub nut from
the axle shaft (Fig. 3).
(6) Disconnect the ABS wheel speed sensor wire
from under the hood. Remove the sensor wire from
the frame and steering knuckle if equipped.
(7) Back off the hub/bearing mounting bolts 1/4
inch each (Fig. 4). Then tap the bolts with a hammer
to loosen the hub/bearing from the steering knuckle.
(8) Remove the hub/bearing mounting bolts and
remove the hub/bearing.
Puller C-3894±A
Remover, Wheel Stud C-4150A
Fig. 2 Hub Extension
1 - HUB EXTENSION
2 - HUB
Fig. 3 Hub Nut Cotter Pin
1 - HUB NUT
2 - COTTER PIN
Fig. 4 Hub/Bearing Mounting Bolts
1 - SOCKET AND EXTENSION
2 - ROTOR AND HUB
3 - STEERING KNUCKLE
2 - 16 FRONT - 4WDBR/BE
FRONT - 4WD (Continued)

(9) Remove the rotor assembly (Fig. 5), brake
shield and spacer from the steering knuckle.
(10) Press out the wheel studs/hub extension studs
and separate the rotor from the hub (Fig. 6).
(11) Remove the wheel speed sensor (Fig. 7) from
the hub bearing if equipped.
INSTALLATION
(1) Install the wheel speed sensor in the hub bear-
ing if equipped.
(2) Position the rotor on the hub/bearing.
(3) Press the wheel studs/hub extension studs
through the back side of the rotor and through the
hub bearing flange (Fig. 8).
Fig. 5 Rotor Hub/Bearing Assembly
1 - ROTOR AND HUB
2 - UNIT BEARING ASSEMBLY
3 - SEAL
Fig. 6 Rotor And Hub/Bearing
1 - HUB BEARING
2 - ROTOR
Fig. 7 Wheel Speed Sensor
1 - HUB BEARING
2 - WHEEL SPEED SENSOR
Fig. 8 Rotor, Hub/Bearing And Stud
1 - HUB BEARING
2 - ROTOR
3 - STUD
BR/BEFRONT - 4WD 2 - 17
HUB / BEARING (Continued)

(4) Apply a liberal quantity of anti-seize compound
to the splines of the front drive shaft.
(5) Insert the two rearmost, top and bottom rotor
hub bolts in the steering knuckle. Insert the bolts
through the back side of the knuckle so they extend
out the front face as shown.
(6) Position the hub spacer (Fig. 9) and brake
shield (Fig. 10) on bolts just installed in knuckle.
NOTE: If the vehicle is equipped with a wheel speed
sensor the brake shield must be positioned on the
hub bearing (Fig. 11).
(7) Align the rotor hub with the drive shaft and
start the shaft into the rotor hub splines.
NOTE: Position wheel speed sensor wire at the top
of the knuckle if equipped.
(8) Align the bolt holes in the hub bearing flange
with the bolts installed in the knuckle. Then thread
the bolts into the bearing flange far enough to hold
the assembly in place.
(9) Install the remaining bolts. Tighten the hub/
bearing bolts to 166 N´m (122 ft. labs.
(10) Install the washer and hub nut and tighten to
245 N´m (180 ft. lbs.).
(11) Install a new cotter pin in the hub nut.
Tighten the nut as needed to align the cotter pin hole
in the shaft with the opening in nut.
(12) Install the brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(13) Install the sensor wire to the steering knuckle
and frame and if equipped. Connect the wheel speed
sensor wire under the hood.(14) Install the wheel and tire assemblies, (Refer
to 22 - TIRES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(15) Remove the support and lower the vehicle.
(16) Apply the brakes several times to seat the
brake shoes and caliper piston. Do not move the vehi-
cle until a firm brake pedal is obtained.
Fig. 9 Hub Spacer
1 - ROTOR HUB BOLTS
2 - HUB SPACER (POSITION FLAT TO REAR)
3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
Fig. 10 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
3 - STEERING KNUCKLE
Fig. 11 Brake Shield With Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
2 - HUB BEARING
3 - SHIELD
2 - 18 FRONT - 4WDBR/BE
HUB / BEARING (Continued)

KNUCKLE
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 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.
UPPER CONTROL ARM
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the upper suspension arm nut and bolt
at the axle bracket (Fig. 12).
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm.
INSTALLATION
(1) Position the upper suspension arm at the axle
and frame rail.
(2) Install the bolts and finger tighten the nuts.
(3) Remove the supports and lower the vehicle.
(4) Tighten nut at the axle bracket to 163 N´m
(120 ft. lbs.). Tighten nut at frame bracket to 163
N´m (120 ft. lbs.).
UPPER BALL JOINT
REMOVAL - DANA 44 & 60
(1) Position tools as shown to remove upper ball
stud (Fig. 13).
Fig. 12 Upper and Lower Suspension Arm
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
Fig. 13 UPPER BALL JOINT REMOVAL
1 - SPECIAL TOOL C4212-F
2 - SPECIAL TOOL 6761
3 - KNUCKLE
4 - SPECIAL TOOL 8445-3
BR/BEFRONT - 4WD 2 - 19

DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT......................1
FRONT AXLE - 248FBI....................14
REAR AXLE - 248RBI.....................46REAR AXLE - 267RBI.....................78
REAR AXLE - 286RBI....................107
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING - PROPELLER
SHAFT...............................1
STANDARD PROCEDURES................3
SPECIFICATIONS
PROPELLER SHAFT....................6
SPECIAL TOOLS
PROPELLER SHAFT....................6
PROPELLER SHAFT - FRONT
REMOVAL.............................6
INSTALLATION..........................7
PROPELLER SHAFT - REAR
REMOVAL.............................7INSTALLATION..........................7
CENTER BEARING
REMOVAL.............................8
INSTALLATION..........................8
ADJUSTMENTS
ADJUSTMENT - CENTER BEARING........8
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY..........................8
ASSEMBLY.............................9
DOUBLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY.........................10
ASSEMBLY............................11
PROPELLER SHAFT
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.
BR/BEDIFFERENTIAL & DRIVELINE 3 - 1

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 propel-
ler shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, properly installed and correctly 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. 1).
(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. 2) 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. 3).
(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 - 2 PROPELLER SHAFTBR/BE
PROPELLER SHAFT (Continued)

Condition Possible Causes Correction
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 wheels and tires.
(3) Remove brake calipers and rotors. Refer to 5
Brakes for procedures.
(4) Remove ABS wheel speed sensors, if equipped.
Refer to 5 Brakes for procedures.
(5) Disconnect axle vent hose.
(6) Disconnect vacuum hose and electrical connec-
tor at disconnect housing.
(7) Remove front propeller shaft.
(8) Disconnect stabilizer bar links at the axle
brackets.
(9) Disconnect shock absorbers from axle brackets.
(10) Disconnect track bar from the axle bracket.
(11) Disconnect tie rod and drag link from the
steering knuckles.
(12) Position suitable lifting device under the axle
assembly.(13) Secure axle to lifting device.
(14) Mark suspension alignment cams for installa-
tion reference.
(15) Disconnect 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.
3 - 18 FRONT AXLE - 248FBIBR/BE
FRONT AXLE - 248FBI (Continued)

(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
(6) Position 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 track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 37 N´m (27 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 88 N´m (65 ft. lbs.).
(11) Install ABS wheel speed sensors, if equipped.
Refer to 5 Brakes for procedures.
(12) Install rotors and brake calipers, refer to 5
Brakes for 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 for lubricant
requirements.
(17) Install wheel and tire assemblies.
(18) Remove supports and lower the vehicle.
(19) Tighten upper suspension arm nuts at axle to
121 N´m (89 ft. lbs.). Tighten upper suspension arm
nuts at frame to 84 N´m (62 ft. lbs.).
(20) Tighten lower suspension arm nuts at axle to
84 N´m (62 ft. lbs.). Tighten the lower suspension
arm nuts at frame to 119 N´m (88 ft. lbs.).
(21) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(22) Check 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. 3). 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 center 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 Backlash and Contact Pattern
in this section for additional information.
Compensation for pinion depth variance is
achieved with a select shim/slinger. The shims are
placed between the rear pinion bearing and the pin-
ion gear head (Fig. 4).
Fig. 3 PINION GEAR ID NUMBERS
1 - PRODUCTION NUMBERS
2 - PINION GEAR DEPTH VARIANCE
3 - GEAR MATCHING NUMBER
Fig. 4 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/SLINGER
2 - DIFFERENTIAL BEARING SHIM
BR/BEFRONT AXLE - 248FBI 3 - 19
FRONT AXLE - 248FBI (Continued)