Page 185 of 2255
Fig. 39 CLUTCH PACK
1 - CLUTCH PACK
2 - SIDE GEAR
3 - PINION GEARS AND MATE SHAFT
4 - ALIGNMENT MARKS
Fig. 40 CASE HALF BOLTS
1 - FIXTURE
2 - CASE BOLTS
3 - TORQUE WRENCH
Fig. 41 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - DIFFERENTIAL
Fig. 42 CASE BEARING INSTALLER
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
3 - 130 REAR AXLE - 286RBIBR/BE
DIFFERENTIAL CASE BEARINGS (Continued)
Page 186 of 2255

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service as a
matched set. Never replace the ring gear without
replacing the matched pinion gear.
(1) Remove differential from the housing.
(2) Place differential case in a vise with soft metal
jaw protectors. (Fig. 43)
(3) Remove the ring gear bolts.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 43).
(5) Remove the exciter ring from the differential
case by tapping it off with a brass drift.
(6) Hold the pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(7) Remove pinion yoke with Remover C-452 and
Wrench C-3281 (Fig. 44).
(8) Remove pinion gear from housing (Fig. 45).
(9) Remove pinion seal with a slide hammer or pry
bar.
(10) Remove oil slinger, if equipped, and the front
pinion bearing.
Fig. 43 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 44 PINION YOKE REMOVER
1 - WRENCH
2 - YOKE
3 - REMOVER
Fig. 45 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
BR/BEREAR AXLE - 286RBI 3 - 131
Page 187 of 2255

(11) Remove front pinion bearing cup with
Remover C-4307 and Handle C±4171 (Fig. 46).
(12) Remove rear bearing cup with Remover D-159
and Handle C-4171 (Fig. 47).
(13) Remove pinion depth shims under rear bear-
ing cup in the housing bore.
(14) Remove rear bearing from the pinion with
Puller/Press C-293-PA and Adapters DD-914-95 (Fig.
48).
INSTALLATION
(1) Apply Mopar Door Ease stick lubricant or
equivalent to outside surface of bearing cups.
(2) Install proper thickness pinion depth shims in
the housing bore and install rear pinion bearing cup
with Installer C-4204 and Handle C-4171 (Fig. 49)
and verify cup is seated.
(3) Install pinion front bearing cup with Installer
C-4308 and Handle C-4171 (Fig. 50) and verify cup is
seated.
Fig. 46 FRONT PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 47 REAR PINION BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 48 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
3 - 132 REAR AXLE - 286RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)
Page 188 of 2255

(4) Install pinion front bearing and oil slinger, if
equipped. Apply a light coating of gear lubricant on
the lip of pinion seal.
(5) Installnewpinion seal with an appropriate
installer (Fig. 51).
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If ring and piniongears are reused, the pinion depth shim should not
require replacement or adjustment. If the ring and
pinion gears are replaced refer to Adjustments to
select the proper thickness shim.
(6) Install rear bearing on the pinion gear with
Installer D-389 and a press (Fig. 52).
(7) Install original solid shims on pinion gears.
(8) Install yoke with Installer C-3718 and Yoke
Holder 6719A (Fig. 53).
(9) Install yoke washer andnewnut on the pinion
gear. Tighten the nut to 637 N´m (470 ft. lbs.).
Fig. 49 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 50 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 51 PINION SEAL
1 - HANDLE
2 - INSTALLER
Fig. 52 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
BR/BEREAR AXLE - 286RBI 3 - 133
PINION GEAR/RING GEAR/TONE RING (Continued)
Page 189 of 2255

(10) Check bearing rotating torque with an inch
pound torque wrench (Fig. 54). Pinion rotating torque
should be:
²Original Bearings: 1 to 3 N´m (10 to 20 in. lbs.).
²New Bearings: 2.8 to 5.1 N´m (25 to 45 in. lbs.).
(11) If rotating torque is less than the desired
rotating torque, remove the pinion yoke and decrease
the thickness of the solid shim pack if greater
increase shim pack. Changing the shim pack thick-
ness by 0.025 mm (0.001 in.) will change the rotating
torque approximately 0.9 N´m (8 in. lbs.).
(12) Invert the differential case.
(13) Position exciter ring on differential case and
tap onto the case with a brass drift slowly and
evenly.
(14) Invert differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(15) Invert the differential case in the vise.
(16) Installnewring gear bolts and alternately
tighten to 298 N´m (220 ft. lbs.) (Fig. 55).
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
(17) Install differential in housing and verify gear
mesh and contact pattern.
Fig. 53 PINION YOKE
1 - INSTALLER
2 - HOLDERFig. 54 Pinion Rotating Torque
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 55 RING GEAR BOLT
1 - TORQUE WRENCH
2 - RING GEAR BOLT
3 - RING GEAR
4 - CASE
3 - 134 REAR AXLE - 286RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)
Page 190 of 2255

BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE........................... 1BRAKES - ABS........................... 35
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
SPECIFICATIONS
BASE BRAKE.........................2
TORQUE CHART......................3
SPECIAL TOOLS
BASE BRAKES........................4
HYDRAULIC/MECHANICAL
DESCRIPTION..........................4
WARNING.............................4
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM.............................5
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING............................7
STANDARD PROCEDURE - PRESSURE
BLEEDING............................8
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING....................8
STANDARD PROCEDURE - ISO FLARING . . . 8
COMBINATION VALVE
DESCRIPTION..........................8
OPERATION............................9
DIAGNOSIS AND TESTING - COMBINATION
VALVE ...............................9
REMOVAL.............................9
INSTALLATION..........................9
DISC BRAKE CALIPERS
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL
REMOVAL - REAR.....................10
REMOVAL - FRONT....................11
DISASSEMBLY.........................11
CLEANING............................12
INSPECTION..........................12ASSEMBLY............................13
INSTALLATION
INSTALLATION - REAR.................14
INSTALLATION - FRONT................14
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION.....................15
STANDARD PROCEDURE - BRAKE FLUID
LEVEL..............................15
SPECIFICATIONS
BRAKE FLUID........................15
FLUID RESERVOIR
REMOVAL.............................15
INSTALLATION.........................15
PEDAL
DESCRIPTION.........................17
OPERATION...........................17
REMOVAL.............................17
INSTALLATION.........................17
POWER BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER...........................18
STANDARD PROCEDURE - BLEEDING......19
REMOVAL.............................19
INSTALLATION.........................19
ROTORS
DIAGNOSIS AND TESTING
DISC BRAKE ROTOR..................20
REMOVAL
REMOVAL - REAR.....................21
REMOVAL - FRONT ± 2500..............22
REMOVAL - FRONT - 3500..............22
INSTALLATION
INSTALLATION - REAR.................22
INSTALLATION - FRONT ± 2500..........23
INSTALLATION - FRONT - 3500...........23
BR/BEBRAKES 5 - 1
Page 191 of 2255

BRAKE PADS/SHOES
REMOVAL
REMOVAL - REAR.....................23
REMOVAL - FRONT....................24
INSTALLATION
INSTALLATION - REAR.................25
INSTALLATION - FRONT................26
MASTER CYLINDER
DESCRIPTION.........................26
OPERATION...........................26
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER...........26
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING..................27
REMOVAL.............................27
INSTALLATION.........................28
PARKING BRAKE
DESCRIPTION.........................28
OPERATION...........................28
PEDAL
REMOVAL.............................28
INSTALLATION.........................29CABLES
REMOVAL
REMOVAL - REAR PARK BRAKE CABLE . . . 29
REMOVAL - FRONT PARKING BRAKE
CABLE..............................29
INSTALLATION
INSTALLATION - REAR PARK BRAKE
CABLE..............................30
INSTALLATION - FRONT PARKING BRAKE
CABLE..............................30
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT........................30
RELEASE HANDLE
REMOVAL.............................31
INSTALLATION.........................32
SHOES
REMOVAL.............................32
INSTALLATION.........................32
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 33
BRAKES - BASE
SPECIFICATIONS
BASE BRAKE
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Front/Rear Disc Brake
Caliper
TypeDual Piston Sliding
Front Disc Brake Caliper
Piston Diameter HD56 mm (2.00 in.)
Front Disc Brake Rotor 326.5ý36 mm
(12.5ý1.5 in.)
Front/Rear Disc Brake
Rotor
Max. Runout0.127 mm (0.005 in.)
Front/Rear Disc Brake
Rotor
Max. Thickness Variation0.025 mm (0.001 in.)
DESCRIPTION SPECIFICATION
Minimum Front Rotor
Thickness33.90 mm (1.334 in.)
Mininium Rear Rotor
Thickness28.39 mm (1.117 in)
Rear Disc Brake Caliper
25002x45 mm (1.77 in)
Rear Disc Brake Caliper
35002x51 mm (2.00 in)
Rear Disc Brake Rotor
2500/3500323.5x30 mm (1.18 in)
Brake Booster
Type
2500 Gasoline EnginesVacuum Dual Diaphragm
Brake Booster
Type
All 3500/
2500 Diesel Engines
OnlyHydraulic
5 - 2 BRAKES - BASEBR/BE
Page 192 of 2255
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Booster
Mounting Nuts To
Dashpanel28 21 250
Master Cylinder
Mounting Nuts23 17 200
Master Cylinder
Brake Lines21 16 190
Combination Valve
Mounting Bolt23 17 210
Combination Valve
Brake Lines21 16 190
Proportioning Valve
Mounting Nuts34 25 300
Proportioning Valve
Brake Hose31 23 276
Proportioning Valve
Brake Lines21 16 190
Front Caliper
Mounting Bolts33 24 Ð
Front Caliper
HD Adapter Bolts285 210 Ð
Rear Caliper
Slide Pins33 24 300
Rotor to Hub Rear
Bolt128 95 Ð
All Caliper
Banjo Bolts40 30 360
Support Plate
Mounting Bolts58 43 Ð
Park Brake Pedal
Assembly
Mounting Bolts/Nuts28 21 250
Hub/Bearing
HD 4x2 Spindle Nut380 280 Ð
Hub/Bearing
4x4 Hub/Bearing Bolts170 125 Ð
BR/BEBRAKES - BASE 5 - 3
BRAKES - BASE (Continued)