2002 DODGE RAM torque

(13) Rotate dial indicator out of the way on the
pilot stud.
(14) Remove differential case and dummy bearings
from the housing.(15) Install the pinion gear in the housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(16) Install differential case and dummy bearings
D-343 in the housing (without shims), install bearing
caps and tighten bolts snug.
(17) Seat ring gear side dummy bearing (Fig. 13).
(18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 14).
(19) Push and hold differential case toward pinion
gear and zero the dial indicator (Fig. 17).
Fig. 14 DIFFERENTIAL SIDE PLAY MEASUREMENT
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 TO RING GEAR SIDE
1 - DIAL INDICATOR
2 - DIFFERENTIAL CASE TO RING GEAR SIDE
3 - DIFFERENTIAL HOUSING
Fig. 17 DIFFERENTIAL CASE TO 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 - 248RBI 3 - 55
REAR AXLE - 248RBI (Continued)

SPECIFICATIONS
REAR AXLE - 248RBI
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.55, 4.10
Ring Gear Diameter 248 mm (9.75 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Gear Standard Depth 127.0 mm (5.000 in.)
Pinion Bearing Preload - Original Bearings 1-2 N´m (10-20 in. lbs.)
Pinion Bearing Preload - New Bearings 2.3-5.1 N´m (20-45 in. lbs.)
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fill Hole Plug 34 25 -
Differential Cover Bolts 41 30 -
Bearing Cap Bolts 108 80 -
Ring Gear Bolt 176 130 -
Pinion Nut 292-447 215-330 -
Axle Shaft Bolts 122-136 90-100 -
Hub Bearing Nut 163-190 120-140 -
SPECIAL TOOLS
REAR AXLE - 248RBI
Puller 6790
Wrench DD-1241-JD
Installer 5064
Installer D-111
BR/BEREAR AXLE - 248RBI 3 - 59
REAR AXLE - 248RBI (Continued)

PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Mark universal joint, pinion yoke and shaft for
installation reference.
(3) Disconnect the propeller shaft from the pinion
yoke.
(4) Remove the wheel and tire assemblies.
(5) Remove brake calipers to prevent any drag
that may cause a false bearing preload torque mea-
surement.
(6) Rotate pinion yoke three or four times.
(7) Record pinion gear rotating torque with an
inch pound torque wrench (Fig. 22).
(8) Hold yoke with Yoke Holder 6719A and remove
the pinion shaft nut and washer.
(9) Remove yoke with Remover C-452 (Fig. 23).
(10) Remove pinion seal with pry tool or slide-
hammer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with an aproppriate
installer (Fig. 24).
(3) Install yoke on pinion shaft with Installer
C-3718 and Yoke Holder 6719.(4) Install pinion yoke washer with theconcave
surfaceagainst the yoke end.
(5) Installnewpinion nut.
CAUTION: Never exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer, if
equipped, or bearings may result.
(6) Hold pinion yoke with Yoke Holder 6719 and
tighten shaft nut to 291.5 N´m (215 ft. lbs.) (Fig. 25).
Rotate pinion shaft several revolutions to ensure the
bearing rollers are seated.
(7) Rotate pinion shaft with a inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal, plus an additional 0.56
N´m (5 in. lbs.) (Fig. 26).
Fig. 22 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 23 PINION YOKE REMOVER
1 - PINION YOKE
2 - REMOVER
Fig. 24 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
BR/BEREAR AXLE - 248RBI 3 - 63

CAUTION: Never loosen pinion gear nut to decrease
pinion rotating torque and never exceed specified pre-
load torque. If preload torque is exceeded a new pin-ion nut and collapsible spacer, if equipped, must be
installed.
(8) If rotating torque is low, use Yoke Holder 6719
to hold the pinion yoke (Fig. 25) and tighten the pin-
ion shaft nut in 6.8 N´m (5 ft. lbs.) increments until
proper rotating torque is achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(9) Install propeller shaft with reference marks
aligned.
(10) Add gear lubricant to the differential housing,
if necessary.
(11) Install wheel and tire assemblies and lower
the vehicle.
(12)
Pump the brake pedal before moving the vehicle.
DIFFERENTIAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove fill hole plug from the differential
housing cover.
(3) Remove differential housing cover and drain
lubricant from the housing.
(4) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove axle shafts.
(6) Note the orientation of the installation refer-
ence letters stamped on the bearing caps and hous-
ing machined sealing surface (Fig. 27).
Fig. 25 TIGHTEN PINION NUT
1 - DIFFERENTIAL HOUSING
2 - YOKE HOLDER
3 - TORQUE WRENCH
Fig. 26 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
Fig. 27 BEARING CAP IDENTIFICATION
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
3 - 64 REAR AXLE - 248RBIBR/BE
PINION SEAL (Continued)

CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied or adhesion quality will be compro-
mised.
(11) Install the cover and tighten bolts in a criss-
cross pattern to 47 N´m (35 ft. lbs.).
(12) Fill the differential with Mopar Hypoid Gear
Lubricant or equivalent to bottom of the fill plug
hole.(13) Install fill hole plug and tighten to 34 N´m (25
ft. lbs.).
(14) Remove support and lower vehicle.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOKT
The most common problem is a chatter noise when
turning corners. Before removing the unit for repair,
drain, flush and refill the axle with the specified
lubricant. A container of Mopar Trac-loktLubricant
(friction modifier) should be added after repair ser-
vice or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
Fig. 33 DIFFERENTIAL CASE
1 - RAWHIDE HAMMER
Fig. 34 Bearing Cap Reference
1 - REFERENCE LETTERS
2 - REFERENCE LETTERS
Fig. 35 DIFFERENTIAL COVER - TYPICAL
1 - SEALANT SURFACE
2 - SEALANT
3 - SEALANT THICKNESS
BR/BEREAR AXLE - 248RBI 3 - 67
DIFFERENTIAL (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)

(6) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(7) Position a small screw driver in slot of
Threaded Adapter Disc C-6960-3 (Fig. 39) to prevent
adapter from turning.(8) Install Forcing Screw C-6960-4 and tighten
screw to 122 N´m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 40).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 41).
Fig. 39 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
Fig. 40 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
Fig. 41 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
BR/BEREAR AXLE - 248RBI 3 - 69
DIFFERENTIAL - TRAC-LOK (Continued)

(8) Install anewcollapsible preload spacer on pin-
ion shaft (Fig. 60).
(9) Install pinion gear into the housing.
(10) Install yoke with Installer C-3718 and Yoke
Holder 6719A (Fig. 61).
(11) Install pinion yoke washer withconcave sur-
faceagainst the yoke end.
(12) Install anewnut on the pinion gear. Tighten
the nut to 292 N´m (215 ft. lbs.) minimum.Do not
over-tighten.Maximum torque is 447 N´m (330 ft.
lbs.).
CAUTION: Never loosen pinion gear nut to decrease
pinion preload torque and never exceed specified
preload torque. If preload torque is exceeded a new
pinion nut and collapsible spacer must be installed.
(13) Tighten pinion nut with Yoke Holder 6719A,
and a torque wrench set at 447 N´m (330 ft. lbs.).
Crush collapsible spacer until bearing end play is
taken up. Slowly tighten the nut in 6.8 N´m (5 ft.
lbs.) increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 62).
(14) Check bearing rotating torque with an inch
pound torque wrench (Fig. 62). Pinion rotating torque
should be:²Original Bearings-1to3N´m(10to20in.lbs.).
²New Bearings - 2.3 to 5.1 N´m (20 to 45 in. lbs.).
(15) Invert the differential case in the vise.
Fig. 60 COLLASIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - SHOULDER
3 - PINION GEAR
4 - OIL SLINGER
5 - REAR PINION BEARING
Fig. 61 PIONION YOKE INSTALLER
1 - INSTALLER
2 - YOKE HOLDER
Fig. 62 PINION ROTATING TORQUE
1 -TORQUE WRENCH
2 - PINION YOKE
3 - 76 REAR AXLE - 248RBIBR/BE
PINION GEAR/RING GEAR/TONE RING (Continued)