2002 DODGE RAM tow

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. 20 BACKLASH SHIM
BR/BEREAR AXLE - 248RBI 3 - 57
REAR AXLE - 248RBI (Continued)

(19) Push and hold differential case toward pinion
gear and zero the dial indicator (Fig. 17).Fig. 14 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL CASE
2 - DIFFERENTIAL HOUSING
3 - PILOT STUD
4 - DIAL INDICATOR
Fig. 15 DIAL INDICATOR LOCATION
1 - DIFFERENTIAL CASE TO PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR ARM
4 - DIAL INDICATOR FACE
Fig. 16 DIFFERENTIAL CASE RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 17 DIFFERENTIAL CASE PINION GEAR SIDE
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
BR/BEREAR AXLE - 267RBI 3 - 87
REAR AXLE - 267RBI (Continued)

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.
BR/BEREAR AXLE - 267RBI 3 - 89
REAR AXLE - 267RBI (Continued)

(19) Push and hold differential case toward pinion
gear (Fig. 17).
(20) Zero dial indicator face to pointer (Fig. 17).
(21) Push and hold differential case to ring gear
side of the housing and record dial indicator reading
(Fig. 18).(22) This is the thickness shim required on the
ring gear side of the differential case to achieve
proper backlash.
(23) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(24) Rotate dial indicator out of the way on pilot
stud.
(25) Remove differential case and dummy bearings
from the housing.
(26) Install side bearing shims on differential case
hubs.
(27) Install side bearings and cups on differential
case.
(28) Install spreader W-129-B on the housing and
spread housing enough to install differential case.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(29) Install differential case in the housing.
(30) Remove spreader from the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the indicator plunger against a ring
gear tooth (Fig. 19).
Fig. 17 PINION GEAR SIDE
1 - DIAL INDICATOR FACE
2 - DIFFERENTIAL CASE TO PINION GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 18 RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - PINION GEAR
4 - DIFFERENTIAL HOUSING
5 - DIFFERENTIAL CASE
Fig. 19 RING GEAR BACKLASH
1 - DIAL INDICATOR
BR/BEREAR AXLE - 286RBI 3 - 117
REAR AXLE - 286RBI (Continued)

(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 axle housing to the other
(Fig. 20).
(36) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at several
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 ANALYSIS
The ring gear and pinion teeth contact patterns
will show if the pinion depth is correct in the axle
housing. 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) Using a boxed end wrench on a 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. 20 BACKLASH SHIM ADJUSTMENT
3 - 118 REAR AXLE - 286RBIBR/BE
REAR AXLE - 286RBI (Continued)

REMOVAL - FRONT
(1) Raise and support vehicle.
(2) Remove front wheel and tire assembly.
(3) Remove caliper brake hose bolt, washers and
hose (Fig. 8).
(4) Remove caliper mounting bolts.
(5) Tilt the top of the caliper up and remove it
from the adapter.
(6) Remove anti-rattle springs.
NOTE: Upper and lower anti-rattle springs are not
interchangeable.
DISASSEMBLY
(1) Drain the brake fluid from caliper.
(2) C-clamp a block of wood over one piston (Fig.
9).
(3) Take another piece of wood and pad it with
one-inch thickness of shop towels. Place this piece in
the outboard shoe side of the caliper in front of the
other piston. This will cushion and protect caliper
piston during removal (Fig. 10).
(4) To remove the caliper piston directshort
bursts of low pressure airwith a blow gun
through the caliper brake hose port. Use only enough
air pressure to ease the piston out.
Fig. 6 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
Fig. 7 REAR CALIPER
1 - Banjo Bolt
2 - Caliper Pin Bolts
Fig. 8 Caliper
1 - WASHERS
2 - MOUNTING BOLTS
3 - HOSE BOLT
Fig. 9 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
BR/BEBRAKES - BASE 5 - 11
DISC BRAKE CALIPERS (Continued)

CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.
(5) Remove the C-clamp and block of wood from
the caliper and clamp it over the dust boot of the
first piston removed. This will seal the empty piston
bore.
(6) Move the padded piece of wood in front of the
other piston.
(7) Remove the second piston using the same pro-
cedure withshort bursts of low pressure air.
(8) Remove piston dust boots with a suitable pry
tool (Fig. 11).
(9) Remove piston seals from caliper (Fig. 12).
CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Push caliper mounting bolt bushings out of
the boot seals and remove the boot seals from the
caliper (Fig. 13).
(11) Remove caliper bleed screw.
CLEANING
Clean the caliper components with clean brake
fluid or brake clean only. Wipe the caliper and piston
dry with lint free towels or use low pressure com-
pressed air.CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
The piston must be replaced if cracked or scored.
Do not attempt to restore a scored piston surface by
sanding or polishing.
Fig. 10 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 11 Piston Dust Boot Removal
1 - CALIPER
2 - DUST BOOT
Fig. 12 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
5 - 12 BRAKES - BASEBR/BE
DISC BRAKE CALIPERS (Continued)

PEDAL
DESCRIPTION
The brake booster is operated by a suspended type
brake pedal. The pedal pivots on a shaft located in a
mounting bracket attached to the dash panel. The
pedal shaft is supported by bushings in the pedal
and mounting bracket. The brake pedal is attached
to the booster push rod.
OPERATION
When the pedal is depressed, the primary booster
push rod is depressed which move the booster sec-
ondary rod. The booster secondary rod depress the
master cylinder piston.
REMOVAL
(1) Remove knee bolster, (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
(2) Remove brake lamp switch, (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/BRAKE
LAMP SWITCH - REMOVAL).
(3) Remove switches from tabs on brake lamp
switch bracket.
(4) Remove brake lamp switch bracket bolts and
remove bracket (Fig. 25).
(5) Remove clip and washer attaching booster push
rod and slide push rod off pedal.
(6) Remove E-clip from passenger side of pedal
shaft (Fig. 26). Use flat blade screwdriver to pry clip
out of shaft groove.
(7) Push shaft toward driver side of bracket just
enough to expose opposite E-clip. Then remove E-clip
with flat blade screwdriver.(8) Push pedal shaft back and out of passenger
side of bracket (Fig. 26).
(9) Remove pedal shaft, brake pedal, wave washer
and bushings from vehicle.
INSTALLATION
(1) Replace bracket and pedal bushings if neces-
sary. Lubricate shaft bores in bracket and pedal
before installing bushings with Mopar Multi-mileage
silicone grease.
(2) Apply liberal quantity of Mopar multi-mileage
grease to pedal shaft and to pedal and bracket bush-
ings.
(3) Position brake pedal in mounting bracket.
(4) Slide pedal shaft into bracket and through
pedal from passenger side.
(5) Push pedal shaft out driver side of mounting
bracket just enough to allow installation of retaining
E-clip.
(6) Install the wave washer between the bracket
and the pedal bushing on the passenger side.
(7) Push pedal shaft back toward passenger side of
bracket and install remaining E-clip on pedal shaft.
(8) Install booster push rod on brake pedal. Secure
push rod to pedal with washer and retaining clip.
(9) Install brake lamp switch bracket and switch,
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
Fig. 25 Brake Lamp Switch Bracket
1 - PEDAL BRACKET
2 - BRAKELIGHT SWITCH BRACKET
3 - BRACKET SCREWS (2)
Fig. 26 Brake Pedal Mounting (With Automatic
Transmission)
1 - PEDAL SHAFT
2 - SHAFT RETAINING E-CLIPS (2)
3 - BRAKE PEDAL
4 - PEDAL BUSHING (2)
5 - PEDAL MOUNTING BRACKET
BR/BEBRAKES - BASE 5 - 17