2003 DODGE RAM Service Repair Manual

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Page 97 of 2895

DODGE RAM 2003 Service Repair Manual 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, Pinion Block 8177,
Arbor Discs

Page 98 of 2895

DODGE RAM 2003 Service Repair Manual (9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims inserted

(9) Remove the pinion depth gauge components
from the housing
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Differential side bearing preload and gear backlash
is achieved by selective shims inserted between the
bearing cup and the housing. The proper shim thick-
ness can be determined using slip-fit Dummy Bear-
ings 8398 in place of the differential side bearings
and a Dial Indicator C-3339. Before proceeding with
the differential bearing preload and gear backlash
measurements, measure the pinion gear depth and
prepare the pinion for installation. Establishing
proper pinion gear depth is essential to establishing
gear backlash and tooth contact 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 measured. The over-
all shim thickness is the total of the dial indicator
reading, starting point shim thicknesses, and the
preload specification added together. The gear back-
lash 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 side of the differential (Fig.
11).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove side bearings from differential case.(2) Install ring gear if necessary, on differential
case and tighten bolts to specification.
(3) Install Dummy Bearings 8398 on differential
case.
(4) Install differential case in the housing.
(5) Insert Dummy Shims 8107 3.0 mm (0.118 in.)
starting point shims between both dummy bearings
and the housing (Fig. 12).
Fig. 10 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 11 ADJUSTMENT SHIM
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
4 - DIFFERENTIAL BEARING PRELOAD SHIM
5 - COLLAPSIBLE SPACER
Fig. 12 DUMMY SHIM
1 - DUMMY SHIM
2 - DIFFERENTIAL HOUSING
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
DRFRONT AXLE - C205F 3 - 25
FRONT AXLE - C205F (Continued)

Page 99 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow hammer to seat the differ-
ential dummy bearings to each side of the differential
hous

Page 100 of 2895

DODGE RAM 2003 Service Repair Manual (18) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads (Fig. 15).
(19) Push and hold differential case toward pinion.(20) Zero dial indicator face to pointer.
(21)

Page 101 of 2895

DODGE RAM 2003 Service Repair Manual (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 (

Page 102 of 2895

DODGE RAM 2003 Service Repair Manual ²Ring gear too far away from pinion gear (Fig.
23). Decrease backlash, by moving the ring closer to
the pinion gear.
²Ring gear too close to pinion gear (Fig. 24).
Increase backlash, by moving the r

Page 103 of 2895

DODGE RAM 2003 Service Repair Manual TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Mounting Nuts 95 70 -
Differential Fill Hole Plug 34 25 -
Differential Cover Bolts 22 15 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
P

Page 104 of 2895

DODGE RAM 2003 Service Repair Manual REMOVER 8401
REMOVER 8831
INSTALLER 8695
INSTALLER 8694
INSTALLER 8693
INSTALLER 8692
INSTALLER 6448
REMOVER C-4660-A
CUP 8150
DRFRONT AXLE - C205F 3 - 31
FRONT AXLE - C205F (Continued)

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