2003 DODGE RAM Service Repair Manual

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Page 105 of 2895

DODGE RAM 2003 Service Repair Manual INSTALLER 5063
PINION BLOCK 8177
PINION DEPTH SET 6775
SPREADER W-129-B
PILOTS C-3288-B
DIAL INDICATOR C-3339
DUMMY SHIM 8107
DUMMY BEARING 8398
INSTALLER C-3718
ADAPTER PLATES 8142A
3 - 32 FRONT AXLE

Page 106 of 2895

DODGE RAM 2003 Service Repair Manual AXLE SHAFTS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove snap ring from the axle shaft.
(5) Remove axle with Remove 8420A Collar

AXLE SHAFTS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove snap ring from the axle shaft.
(5) Remove axle with Remove 8420A Collar 8420-3
and Slide Hammer C-3752 (Fig. 27).
INSTALLATION
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(1) Lubricate bearing bore and seal lip with gear
lubricant.
(2) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
(3) Check the differential fluid level and add fluid
if necessary.
(4) Install skid plate, if necessary.
(5) Install half shaft.
AXLE SHAFT SEALS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal with a small pry bar.
INSTALLATION
(1) Clean axle shaft bore clean.
(2) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(3) Lubricate seal lip with gear lubricant.
(4) Insert axle shaft through seal, bearing, and
engage it into side gear splines. Push firmly on the
axle shaft to engage the snap-ring.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(5) Install axle shaft O-ring.
(6) Check the differential fluid level and add fluid
if necessary.
(7) Install skid plate, if necessary.
(8) Install half shaft.
AXLE BEARINGS
REMOVAL
(1) Remove half shaft from vehicle.
(2) Remove skid plate, if equipped.
(3) Clean axle seal area.
(4) Remove axle shaft O-ring.
(5) Remove axle shaft.
(6) Remove axle shaft seal.
(7) Install axle shaft bearing Remover C-4660-A in
the bearing (Fig. 28). Then tighten the nut to spread
the remover in the bearing.
(8) Install the bearing remove cup, bearing and
nut (Fig. 29). Then tighten the nut to draw the bear-
ing out.
Fig. 27 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 28 BEARING REMOVER
1 - AXLE BEARING
2 - NUT
3 - REMOVER
DRFRONT AXLE - C205F 3 - 33

Page 107 of 2895

DODGE RAM 2003 Service Repair Manual (9) Inspect the axle shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
(1) Wipe the axle shaft tube bore clean.
(2) Install axle shaft bearing with Installer 5063
and Handle C

Page 108 of 2895

DODGE RAM 2003 Service Repair Manual INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Install seal with Installer 8695 and Handle
C-4171 (Fig. 34).
(3) Install companion flange onto the pinion with

Page 109 of 2895

DODGE RAM 2003 Service Repair Manual CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer mus

CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed.
(6) Record pinion rotating torque using an inch
pound torque wrench. The rotating torque should be
equal to the reading recorded during removal plus an
additional 0.56 N´m (5 in. lbs.) (Fig. 36).
(7) If rotating torque is low, tighten the pinion nut
in 6.8 N´m (5 ft. lbs.) increments until the proper
rotating torque is achieved.
CAUTION: If maximum tightening torque 475 N´m
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Replace the collapsible
spacer.
(8) Install propeller shaft with reference marks
aligned.
(9) Add gear lubricant to differential housing if
necessary.
(10) Install half shafts and skid plate if equipped.DIFFERENTIAL
DESCRIPTION
The differential case is a one-piece design. The dif-
ferential pinion shaft is retained with a snap ring.
Differential bearing preload and ring gear backlash
is adjusted by the use of adjusters. The adjuster are
between the differential bearings and the differential
housing. Pinion bearing preload is set and main-
tained by the use of a collapsible spacer. The
stamped steel cover provides a means for inspection
and servicing the differential.
OPERATION
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.
37).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
38). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
speed.
REMOVAL
(1) Remove differential housing cover and drain
fluid.
Fig. 36 PINION ROTATION TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 37 DIFFERENTIAL-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 - 36 FRONT AXLE - C205FDR
PINION SEAL (Continued)

Page 110 of 2895

DODGE RAM 2003 Service Repair Manual (2) Remove axle shafts.
(3) Loosen bearing cap bolts.
NOTE: Differential bearing cap reference numbers
are stamped on caps and machined flat on the
housing. If reference numbers cannot be found,
make

Page 111 of 2895

DODGE RAM 2003 Service Repair Manual ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install pinion mate gears and thrust washers.
(3) Install pinion gear mate shaft.
(4) Align the hole in the pinion gear mate shaf

Page 112 of 2895

DODGE RAM 2003 Service Repair Manual (3) Spread housing and measure the distance with
the dial indicator.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(4) Remove dial ind

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