2002 DODGE RAM height

PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indi-
cator C-3339 (Fig. 6).(1) Assemble Pinion Height Block 6739, Pinion
Block 6737 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 6).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
Fig. 6 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 7 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
3 - 84 REAR AXLE - 267RBIBR/BE
REAR AXLE - 267RBI (Continued)

(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 108 N´m (80 ft. lbs.).
(6) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(7) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim/oil baffle equal to the dial indica-
tor reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 4). For example,
if the depth variance is ±2, add +0.002 in. to the dial
indicator reading.
DIFFERENTIAL SIDE BEARING PRELOAD AND
GEAR BACKLASH
Differential side bearing preload and gear backlash is
achieved by selective shims positioned behind the differ-
ential side bearing cones. The proper shim thickness
can be determined using slip-fit Dummy Bearings D-343
in place of the differential side bearings and a Dial Indi-
cator C-3339. Before proceeding with the differential
bearing preload and gear backlash measurements, mea-
sure the pinion gear depth and prepare the pinion for
installation. Establishing proper pinion gear depth is
essential to establishing gear backlash and tooth con-
tact 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 mea-
sured. The overall shim thickness is the total of the dial
indicator reading and the preload specification addedtogether. 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 differ-
ential (Fig. 10). Differential shim measurements are
performed with spreader W-129-B removed.
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 10 SHIM LOCATIONS
1 - PINION GEAR DEPTH SHIM/OIL BAFFLE
2 - DIFFERENTIAL BEARING SHIM
BR/BEREAR AXLE - 267RBI 3 - 85
REAR AXLE - 267RBI (Continued)

REAR AXLE - 286RBI
TABLE OF CONTENTS
page page
REAR AXLE - 286RBI
DESCRIPTION........................107
OPERATION..........................108
DIAGNOSIS AND TESTING - AXLE.........108
REMOVAL............................112
INSTALLATION........................112
ADJUSTMENTS.......................112
SPECIFICATIONS
REAR AXLE - 286RBI.................120
SPECIAL TOOLS
REAR AXLE - 286 RBI.................120
AXLE SHAFTS
REMOVAL............................123
INSTALLATION........................123
AXLE BEARINGS
REMOVAL............................123
INSTALLATION........................123
PINION SEAL
REMOVAL............................123INSTALLATION........................124
DIFFERENTIAL
REMOVAL............................125
DISASSEMBLY........................126
ASSEMBLY...........................126
INSTALLATION........................126
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT....128
DISASSEMBLY........................128
ASSEMBLY...........................129
DIFFERENTIAL CASE BEARINGS
REMOVAL............................129
INSTALLATION........................129
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................131
INSTALLATION........................132
REAR AXLE - 286RBI
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 into the differential housing and
welded. The axles are full-floating axle shafts, that
are supported by the axle housing tubes. The full-
float axle shafts are retained by bolts attached to the
hub.
The differential case for the standard differential is
a one-piece design. Differential bearing preload and
ring gear backlash are adjusted by the use of shims
located between the differential bearing cones andcase. Outboard protective spacers are located
between the differential bearing cup and housing.
Pinion bearing preload is set and maintained by the
use of shims. Pinion height is controlled by a shim
pack located under the inner pinion bearing cup. The
differential cover provides a means for inspection and
service.
Axles equipped with a Trac-Loktdifferential are
optional. The differential 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 addition to the standard differential compo-
nents. A Trac-loktdifferential for the has a two-piece
differential case.
BR/BEREAR AXLE - 286RBI 3 - 107

thousands of an inch deviation from the standard. If the
number is negative, add that value to the required
thickness of the depth shim(s). If the number is posi-tive, subtract that value from the thickness of the depth
shim(s). If the number is 0 no change is necessary. Refer
to the Pinion Gear Depth Variance Chart.
PINION GEAR DEPTH VARIANCE
Original
Pinion
Gear
Depth
VarianceReplacement Pinion Gear Depth Variance
24232221 0 +1 +2 +3 +4
+4+0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3+0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.001
+2+0.006 +0.005 +0.004 +0.003 +0.002 +0.001 020.00120.002
+1+0.005 +0.004 +0.003 +0.002 +0.001 020.00120.00220.003
0+0.004 +0.003 +0.002 +0.001 020.00120.00220.00320.004
21+0.003 +0.002 +0.001 020.00120.00220.00320.00420.005
22+0.002 +0.001 020.00120.00220.00320.00420.00520.006
23+0.001 020.00120.00220.00320.00420.00520.00620.007
24020.00120.00220.00320.00420.00520.00620.00720.008
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion cups and pin-
ion bearings installed in housing. Take measure-
ments with a Pinion Gauge Set 6730 and Dial
Indicator C-3339 (Fig. 6).
(1) Assemble Pinion Height Block 6739, Pinion
Block 6738 and rear pinion bearing onto Screw 6741
(Fig. 6).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 7).
(3) Install front pinion bearing and Cone 6740
hand tight (Fig. 6).
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 8).
Install differential bearing caps on Arbor Discs and
snug the bearing cap bolts. Then tighten cap bolts in
a criss-cross pattern to 108 N´m (80 ft. lbs.).
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(6) Position Scooter Block/Dial Indicator flush on
the pinion height block. Hold scooter block and zero
the dial indicator.
(7) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 9). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
Fig. 6 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
BR/BEREAR AXLE - 286RBI 3 - 113
REAR AXLE - 286RBI (Continued)

(8) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 4) using
the opposite sign on the variance number. For exam-
ple, if the depth variance is ±2, add +0.002 in. to the
dial indicator reading.
(9) Remove the pinion depth gauge components
from the axle housing
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims positioned behind thedifferential side bearing cones. The proper shim
thickness can be determined using slip-fit dummy
bearings D-346 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 gear for installation. Estab-
lishing proper pinion gear depth is essential to estab-
lishing gear backlash and tooth contact patterns.
After the overall shim thickness to take up differen-
tial side play is measured, the pinion gear is
installed, and the gear backlash shim thickness is
measured. The overall shim thickness is the total of
the dial indicator reading and the preload specifica-
tion 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 differential (Fig. 10). Differential
shim measurements are performed with axle
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, if necessary.
Fig. 7 PINION HEIGHT BLOCK
1 - PINION BLOCK
2 - PINION HEIGHT BLOCK
Fig. 8 GAUGE TOOLS IN HOUSING
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
4 - PINION HEIGHT BLOCK
Fig. 9 PINION DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
3 - 114 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)

CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consist of the brake shoes,
calipers, wheel cylinders, brake drums, rotors, brake
lines, master cylinder, booster, and parking brake
components.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum
operated component.
The first diagnosis step is the preliminary check.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires
can cause pull, shudder, vibration, and a condition
similar to grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering
components.
(3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear.Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake
lines, and master cylinder.
(b) If fluid appears contaminated, drain out a
sample to examine. System will have to be flushed
if fluid is separated into layers, or contains a sub-
stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system.
(4) Check parking brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parking
brake partially applied.
(5) Check brake pedal operation. Verify that pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
being loose or for bind condition. Do not road test
until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
ROAD TESTING
(1) If complaint involved low brake pedal, pump
pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
firm under constant foot pressure.
(3) During road test, make normal and firm brake
stops in 25-40 mph range. Note faulty brake opera-
tion such as low pedal, hard pedal, fade, pedal pulsa-
tion, pull, grab, drag, noise, etc.
(4) Attempt to stop the vehicle with the parking
brake only and note grab, drag, noise, etc.
PEDAL FALLS AWAY
A brake pedal that falls away under steady foot
pressure is generally the result of a system leak. The
leak point could be at a brake line, fitting, hose, or
caliper/wheel cylinder. If leakage is severe, fluid will
be evident at or around the leaking component.
Internal leakage (seal by-pass) in the master cylin-
der caused by worn or damaged piston cups, may
also be the problem cause.
An internal leak in the ABS or RWAL system may
also be the problem with no physical evidence.
LOW PEDAL
If a low pedal is experienced, pump the pedal sev-
eral times. If the pedal comes back up, worn linings,
rotors, drums, or rear brakes out of adjustment are
the most likely causes. The proper course of action is
to inspect and replace all worn component and make
the proper adjustments.
BR/BEBRAKES - BASE 5 - 5
HYDRAULIC/MECHANICAL (Continued)

²Terminal number 30 is connected to battery volt-
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times.
²The PCM grounds the coil side of the relay
through terminal number 85.
²Terminal number 86 supplies voltage to the coil
side of the relay.
²When the PCM de-energizes the ASD and fuel
pump relays, terminal number 87A connects to termi-
nal 30. This is the Off position. In the off position,
voltage is not supplied to the rest of the circuit. Ter-
minal 87A is the center terminal on the relay.
²When the PCM energizes the ASD and fuel
pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
(6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
power source.Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wire to
relay terminal 86. This activates the relay. The ohm-
meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the ASD
and fuel pump relay circuits. Refer to 8, Wiring Dia-
grams.
REMOVAL
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 3). Refer to label on PDC cover
for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 3). Refer to label on PDC cover
for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
Fig. 3 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
BR/BEIGNITION CONTROL 8I - 5
AUTOMATIC SHUT DOWN RELAY (Continued)

SPORT
(1) Position fog lamp in fascia.
(2) Install screws attaching fog lamp to fascia.
(3) Connect wire connector to fog lamp.
(4) Connect the battery negative cable.
(5) Check for proper operation and beam align-
ment.
ADJUSTMENTS
Prepare an alignment screen. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - ADJUSTMENTS)
A properly aligned fog lamp will project a pattern
on the alignment screen 100 mm (4 in.) below the fog
lamp centerline and straight ahead (Fig. 12).
To adjust fog lamp aim, rotate adjustment screw on
the rear of fog lamp to achieve the specified height.
HEADLAMP
DESCRIPTION
Headlamps on the Ram Pick-Up are modular in
design. The turn/park lamp module is incorporated
into the headlamp module. The module contains two
bulbs; a dual filament headlamp bulb, and a dual fil-
ament turn/park bulb. The Sport headlamp module
has two separate bulbs for the headlamp illumina-
tion.
OPERATION
Headlamps and parking lamps are controlled by
the headlamp switch. The multifunction switch
mounted on the steering column controls the high
beam function, and the turn signal function.
Fig. 12 Fog Lamp Alignment
1 - VEHICLE CENTERLINE
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS5 - 100 mm (4 in.)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
BR/BELAMPS/LIGHTING - EXTERIOR 8L - 13
FOG LAMP UNIT (Continued)