2002 DODGE RAM service

INSTALLATION
(1) Install differential side bearings with Installer
C-4190 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Do not replace the ring gear without
replacing the match pinion gear.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft metal
jaw.
(3) Remove ring gear bolts from differential case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 47).
(5) Mark pinion yoke and propeller shaft for
installation alignment.(6) Remove propeller shaft from pinion yoke and
tie propeller shaft to underbody.
(7) Hold pinion yoke with Holder 6719A and
remove pinion yoke nut and washer.
(8) Remove pinion yoke with Puller C-452 and
Flange Wrench C-3281 (Fig. 48).
Fig. 46 Install Differential Side Bearings
1 - HANDLE
2 - DIFFERENTIAL CASE
3 - BEARING
4 - INSTALLER
Fig. 47 RING GEAR
1 - CASE
2 - RING GEAR
3 - HAMMER
Fig. 48 PINION YOKE
1 - FLANGE WRENCH
2 - YOKE
3 - PULLER
BR/BEFRONT AXLE - 248FBI 3 - 41
DIFFERENTIAL CASE BEARINGS (Continued)

REAR AXLE - 248RBI
TABLE OF CONTENTS
page page
REAR AXLE - 248RBI
DESCRIPTION.........................46
OPERATION...........................46
DIAGNOSIS AND TESTING - AXLE..........47
REMOVAL.............................51
INSTALLATION.........................51
ADJUSTMENTS........................51
SPECIFICATIONS
REAR AXLE - 248RBI..................59
SPECIAL TOOLS
REAR AXLE - 248RBI..................59
AXLE SHAFTS
REMOVAL.............................62
INSTALLATION.........................62
AXLE BEARINGS
REMOVAL.............................62
INSTALLATION.........................62
PINION SEAL
REMOVAL.............................63INSTALLATION.........................63
DIFFERENTIAL
REMOVAL.............................64
DISASSEMBLY.........................65
ASSEMBLY............................66
INSTALLATION.........................66
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT.....67
DISASSEMBLY.........................68
ASSEMBLY............................70
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................72
INSTALLATION.........................72
PINION GEAR/RING GEAR/TONE RING
REMOVAL.............................73
INSTALLATION.........................75
REAR AXLE - 248RBI
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 equipped with full-floating axle shafts, meaning
that loads are supported by the axle housing tubes.
The differential case for the standard differentials
and the Trac-loktdifferential are a one-piece design.
Differential bearing preload and ring gear backlash
are adjusted by the use of shims located between the
differential bearing cones and case. Pinion bearing
preload is set and maintained by the use of a collaps-
ible spacer. The removable, stamped steel cover pro-
vides a means for inspection and service.
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shaftsthrough the pinion mate and side gears. The side
gears are splined to the axle shafts.
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).Fig. 1 STRAIGHT AHEAD DRIVING
1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 - PINION GEAR
3 - SIDE GEAR
4 - PINION GEARS ROTATE WITH CASE
3 - 46 REAR AXLE - 248RBIBR/BE

DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
BR/BEREAR AXLE - 248RBI 3 - 49
REAR AXLE - 248RBI (Continued)

Note the etched number on the face of the pinion
gear head (±1, ±2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to therequired thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
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 6736 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.
(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
Fig. 6 PINION 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
3 - 52 REAR AXLE - 248RBIBR/BE
REAR AXLE - 248RBI (Continued)

(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 36).
(6) If rotating torque is less than 41 N´m (56 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 37).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-loktdifferential can be serviced
with the ring gear installed.
(3) Remove pinion gear mate shaft roll pin.
(4) Remove pinion gear mate shaft with a drift and
hammer.
(5) Install and lubricate Step Plate C-6960-3 (Fig.
38).
Fig. 36 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 37 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 38 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
3 - 68 REAR AXLE - 248RBIBR/BE
DIFFERENTIAL - TRAC-LOK (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service as a
matched set. Never replace ring gear without
replacing the matched pinion gear.
(1) Remove differential from housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 49)
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from the differential case with
a soft hammer (Fig. 49).
(5) Remove exciter ring from the differential case
by slowly tapping the ring with a brass drift.
(6) Mark pinion yoke and propeller shaft for
installation alignment.
(7) Disconnect propeller shaft from pinion yoke
and tie propeller shaft to underbody.
(8) Hold yoke with Yoke Holder 6719A and remove
pinion yoke nut and washer.
(9) Remove pinion yoke with Remover C-452 and
Flange Wrench C-3281 (Fig. 50).
(10) Remove pinion gear from housing (Fig. 51).
(11) Remove pinion seal with a slide hammer or
suitable pry bar.
(12) Remove oil slinger, if equipped, and front pin-
ion bearing.
(13) Remove front pinion bearing cup with
Remover D-158 and Handle C±4171 (Fig. 52).(14) Remove rear bearing cup with Remover D-162
and Handle C-4171 (Fig. 53).
(15) Remove collapsible preload spacer (Fig. 54)
from pinion gears.
(16) Remove rear pinion bearing with Puller/Press
C-293-PA and Adapters C-293-37 (Fig. 55).
(17) Remove pinion depth shims from the pinion
shaft and record thickness of the depth shims.
Fig. 49 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 50 PINION YOKE REMOVER
1 - FLANGE WRENCH
2 - PINION YOKE
3 - REMOVER
Fig. 51 PINION GEAR REMOVAL
1 - RAWHIDE HAMMER
BR/BEREAR AXLE - 248RBI 3 - 73

REAR AXLE - 267RBI
TABLE OF CONTENTS
page page
REAR AXLE - 267RBI
DESCRIPTION.........................78
OPERATION...........................78
DIAGNOSIS AND TESTING - AXLE..........80
REMOVAL.............................82
INSTALLATION.........................82
ADJUSTMENTS........................83
SPECIFICATIONS
REAR AXLE - 267RBI..................91
SPECIAL TOOLS
REAR AXLE - 267RBI..................91
AXLE SHAFTS
REMOVAL.............................94
INSTALLATION.........................94
AXLE BEARINGS
REMOVAL.............................94
INSTALLATION.........................94
PINION SEAL
REMOVAL.............................94INSTALLATION.........................95
DIFFERENTIAL
REMOVAL.............................96
DISASSEMBLY.........................97
ASSEMBLY............................97
INSTALLATION.........................97
DIFFERENTIAL - POWR-LOK
DIAGNOSIS AND TESTING - POWR-LOKT....99
DISASSEMBLY.........................99
ASSEMBLY............................99
DIFFERENTIAL CASE BEARINGS
REMOVAL............................102
INSTALLATION........................102
PINION GEAR/RING GEAR/TONE RING
REMOVAL............................103
INSTALLATION........................104
REAR AXLE - 267RBI
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, sup-
ported by the axle housing tubes. The full-float 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 and
case. Pinion bearing preload is set and maintained by
the use of a solid shims. The differential cover pro-
vides a means for inspection and service.
Axles equipped with a Powr-loktdifferential are
optional. The differential has a two-piece differentialcase. The differential contains four pinion gears and
a two-piece pinion mate cross shaft to provide
increased torque to the non-slipping wheel through a
ramping motion in addition to the standard Trac-lokt
components.
OPERATION
STANDARD DIFFERENTIAL
The axle receives power from the transmission/
transfer case through the rear propeller shaft. The
rear propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
3 - 78 REAR AXLE - 267RBIBR/BE

DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage. Set
differential bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage. Set
ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
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.
BR/BEREAR AXLE - 267RBI 3 - 81
REAR AXLE - 267RBI (Continued)