2003 DODGE RAM brake sensor

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Remove wheels and tires.
(2) Remove brake calipers and rotors.
(3) Disconnect ABS wheel speed sensors.
(4) Disconnect axle vent hose.
(5) Remove front propeller shaft.
(6) Disconnect stabilizer bar links at the axle
brackets.
(7) Disconnect shock absorbers from axle brackets.
(8) Disconnect track bar from the axle bracket.
(9) Disconnect tie rod and drag link from the steer-
ing knuckles.
(10) Position suitable lifting device under the axle
assembly.
(11) Secure axle to lifting device.
(12) Mark suspension alignment cams for installa-
tion reference.
(13) Disconnect upper and lower suspension arms
from the axle bracket.(14) Lower the axle. The coil springs will drop
with the axle.
(15) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension, at normal height. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur. Rubber bushings must never
be lubricated.
(1) Support the axle on a suitable lifting device.
(2) Secure axle to lifting device.
(3) Position the axle under the vehicle.
(4) Install springs, retainer clip and bolts.
(5) Raise axle and align it with the spring pads.
3 - 48 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

(6) Position upper and lower suspension arms in
the axle brackets. Install bolts, nuts and align the
suspension alignment cams to the reference marks.
Do not tighten at this time.
(7) Connect track bar to the axle bracket and
install the bolt. Do not tighten at this time.
(8) Install shock absorber and tighten bolts to 121
N´m (89 ft. lbs.).
(9) Install stabilizer bar link to the axle bracket.
Tighten the nut to 68 N´m (50 ft. lbs.).
(10) Install drag link and tie rod to the steering
knuckles and tighten the nuts to 108 N´m (80 ft.
lbs.).
(11) Install ABS wheel speed sensors.
(12) Install rotors and brake calipers.
(13) Connect the axle vent hose.
(14) Install front propeller shaft.
(15) Check and add differential lubricant, if neces-
sary.
(16) Install wheel and tire assemblies.
(17) Remove lower the vehicle.
(18) Tighten upper suspension arm nuts at axle to
149 N´m (110 ft. lbs.). Tighten upper suspension arm
nuts at frame to 149 N´m (110 ft. lbs.).
(19) Tighten lower suspension arm nuts at axle to
190 N´m (140 ft. lbs.). Tighten the lower suspension
arm nuts at frame to 190 N´m (140 ft. lbs.).
(20) Tighten track bar bolt at the axle bracket to
176 N´m (130 ft. lbs.).
(21) Check front wheel alignment.
ADJUSTMENTS
Ring and pinion gears are supplied as matched
sets only. Compensation for pinion depth variance is
achieved with a select shim. The shim is located
between the rear pinion bearing and the pinion gear
head.
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. 1).
(1) Assemble Pinion Height Block 6739, Pinion
Block 8878 and rear pinion bearing onto Screw 6741
(Fig. 1).
(2) Insert assembled height gauge components,
rear bearing and screw into the housing through pin-
ion bearing cups (Fig. 2).
(3) Install front pinion bearing and install the
Cone-nut 6740 hand tight. Then check tool rotating
torque with an inch pound torque wrench. The rotat-
ing torque should be 1.7-2.26 N´m (15-20 in. lbs.)
(4) Place Arbor Disc 8289 on Arbor D-115-3 in posi-
tion in the housing side bearing cradles (Fig. 3).(5) Install differential bearing caps on arbor discs
and snug the bearing cap bolts. Then cross tighten
cap bolts to 85 N´m (63 ft. lbs.).
Fig. 1 PINION GEAR 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
Fig. 2 PINION HEIGHT BLOCK
1. PINION HEIGHT BLOCK
2. PINION BLOCK
DRFRONT AXLE - 9 1/4 AA 3 - 49
FRONT AXLE - 9 1/4 AA (Continued)

AXLE SHAFTS
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove brake caliper, rotor and ABS wheel
speed sensor if equipped.
(3) Remove axle shaft cotter pin, hub nut and
washer (Fig. 14).
(4) Remove the four hub bearing bolts (Fig. 15)
from the back of the steering knuckle.
(5) Remove hub bearing from the steering knuckle.
(6) Remove axle shaft (Fig. 16) from steering
knuckle and axle housing.
DISASSEMBLY
Single cardan U-joint components are not service-
able. If defective they must be replaced as a unit.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove the bearing cap retaining snap rings
(Fig. 17).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(2) Locate a socket with an inside diameter that is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
ADAPTERS 8879
ADJUSTER WRENCH 8883
FLANGE WRENCH 8979
FLANGE PULLER 8992
Fig. 14 AXLE NUT
1 - AXLE NUT
2 - AXLE
3 - COTTER PIN
3 - 56 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

ASSEMBLY
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
INSTALLATION
(1) Clean axle shaft and apply a thin film of
Mopar Wheel Bearing Grease to the shaft splines
and hub bore.
(2) Install axle shaft through the steering knuckle
and into the differential side gears (Fig. 19).
CAUTION: Do not damage axle shaft seal during
axle installtion.
(3) Install hub bearing in the knuckle.
(4) Install hub bearing bolts and tighten to 202
N´m (149 ft. lbs.).
(5) Install ABS wheel speed sensor, brake rotor
and caliper.
(6) Install axle washer and nut. Tighten axle nut
to 179 N´m (132 ft. lbs.).(7) Rotate axle several 5 to 10 times to seat the
wheel bearing.
(8) Tighten axle nut to final torque of 356 N´m
(263 ft. lbs.).
(9) Align nut to next cotter pin hole and install
new cotter pin.
(10) Install wheel and tire assembly.
AXLE SHAFT SEALS
REMOVAL
(1) Remove hub bearings and axle shafts.
(2) Remove differential from differential housing.
(3) Remove differential bearing adjusters (Fig. 20).
(4) Remove axle seals (Fig. 21) located behind
adjusters with Receiver 8498 and Extractor 6310.
(5) Install Receiver 8498 into the adjuster bore.
(6) Install Extractor Rod 6310 with Extractor Foot
6310-9 through the receiver and the axle seal (Fig.
22).
(7) Install Extractor Plate 6310-2 and Nut 6310-7
on the extractor rod.
(8) Tighten nut on the extractor rod (Fig. 23) and
pull the seal out and into the receiver.
INSTALLATION
(1) Install axle seal on Installer Cups 8885-2 and
position cups with seals into the housing.
NOTE: Seal are installed with the axle guide facing
outward.
Fig. 19 AXLE SHAFT
1 - AXLE YOKE
2 - AXLE SHAFT
3 - KNUCKLE
Fig. 20 ADJUSTERS
1 - DIFFERENTIAL CASE BEARING ADJUSTERS
2 - DIFFERENTIAL HOUSING
3 - 58 FRONT AXLE - 9 1/4 AADR
AXLE SHAFTS (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Position a lifting device under the axle.
(3) Secure axle to device.
(4) Remove wheels and tires assemblies.
(5) Remove RWAL sensor from the differential
housing.
(6) Remove brake hose at the axle junction block.
(7) Disconnect parking brake cables and cable
brackets.
(8) Remove brake calipers and rotors.
(9) Remove axle vent hose.
(10) Mark propeller shaft and companion flange
for installation alignment reference.
(11) Remove propeller shaft.
(12) Remove shock absorbers from axle.
(13) Remove U-bolets from axle.
(14) Separate the axle from the vehicle.
INSTALLATION
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install the RWAL sensor to the differential
housing.
(5) Connect the parking brake cables and cable
brackets.
(6) Install brake rotors and calipers.
(7) Connect brake hose to the axle junction block.
(8) Install axle vent hose.
(9) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(10) Install the wheels and tires.
(11) Fill differential to specifications.
(12) Remove lifting device from axle and lower the
vehicle.
ADJUSTMENTS
Ring gear and pinion are supplied as matched sets
only. The identifying numbers for the ring gear and
pinion are painted onto the pinion gear shaft (Fig. 2)
and the side of the ring gear. A plus (+) number,
minus (±) number or zero (0) along with the gear set
sequence number (01 to 99) is on each gear. This first
number is the amount (in thousandths of an inch)
the depth varies from the standard depth setting of a
pinion marked with a (0). The next two numbers are
the sequence number of the gear set. The standard
depth provides the best teeth contact pattern. Refer
to Backlash and Contact Pattern for additional infor-
mation.Compensation for pinion depth variance is
achieved with select shims. The shims are placed
behind the rear pinion bearing. (Fig. 3).
If a new gear set is being installed, note the depth
variance painted onto both the original and replace-
ment pinion. Add or subtract the thickness of the
original depth shims to compensate for the difference
in the depth variances. Refer to the Depth Variance
chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the painted number on the shaft of the drive
pinion (±1, ±2, 0, +1, +2, etc.). The numbers repre-
Fig. 2 PINION ID NUMBER
1 - VARIANCE NUMBER
2 - SEQUENCE NUMBER
Fig. 3 ADJUSTMENT SHIM LOCATIONS
1 - DIFFERENTIAL HOUSING
2 - COLLAPSIBLE SPACER
3 - PINION BEARING
4 - PINION DEPTH SHIM
5 - PINION GEAR
6 - BEARING CUP
3 - 74 REAR AXLE-91/4DR
REAR AXLE - 9 1/4 (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position a lifting device under the axle.
(3) Secure axle to device.
(4) Remove wheels and tires assemblies.
(5) Remove RWAL sensor from the differential
housing.
(6) Remove brake hose at the axle junction block
and axle vent hose.
(7) Disconnect parking brake cables and cable
brackets.
(8) Remove brake calipers and rotors.
(9) Mark propeller shaft and companion flange for
installation alignment reference.
(10) Remove propeller shaft.
(11) Remove shock absorbers from axle.
(12) Remove U-bolts from axle.
(13) Separate the axle from the vehicle.
INSTALLATION
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install the RWAL sensor to the differential
housing.
(5) Connect the parking brake cables and cable
brackets.
(6) Install brake calipers.
(7) Connect brake hose to the axle junction block
and axle vent hose.
(8) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(9) Install the wheels and tires.
DRREAR AXLE - 10 1/2 AA 3 - 103
REAR AXLE - 10 1/2 AA (Continued)

Condition Possible Causes Correction
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion
adjustment.2. Check ring gear and pinion
contact pattern. Adjust backlash or
pinion depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
(1) Raise and support the vehicle.
(2) Position a lifting device under the axle.
(3) Secure axle to device.
(4) Remove wheels and tires assemblies.
(5) Remove RWAL sensor from the differential
housing.
(6) Remove brake hose at the axle junction block
and axle vent hose.
(7) Disconnect parking brake cables and cable
brackets.
(8) Remove brake calipers.
(9) Mark propeller shaft and companion flange for
installation alignment reference.
(10) Remove propeller shaft.
(11) Remove shock absorbers from axle.
(12) Remove U-bolets from axle.
(13) Separate the axle from the vehicle.
INSTALLATION
(1) Raise axle with lifting device and align to the
leaf spring centering bolts.
(2) Install axle U-bolts and tighten to 149 N´m
(110 ft. lbs.).
(3) Install shock absorbers to axle and tighten to
specification.
(4) Install the RWAL sensor to the differential
housing.
(5) Connect the parking brake cables and cable
brackets.
(6) Connect brake hose to the axle junction block
and axle vent hose.
(7) Align propeller shaft and pinion companion
flange reference marks and tighten companion flange
bolts to 115 N´m (85 ft. lbs.).
(8) Install the wheels and tires.
(9) Fill differential to specifications.
3 - 130 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11 1/2 AA (Continued)

(5) Remove the banjo bolt at the caliper (Fig. 7).
(6) Remove the hose.
REMOVAL - FRONT HOSE
(1) Install a prop rod on the brake pedal to keep
pressure on the brake system.
(2) Raise and support vehicle.
(3) Remove the tire and wheel assembly.
(4) Remove the brake hose from the brake line
located at the frame (Fig. 8).
(5) Remove the brake hose banjo bolt at the caliper
(Fig. 8).
(6) Remove the mounting bolt securing the brake
hose to the frame and remove the wheel speed sensor
wire from the brake hose (Fig. 8).
(7) Remove the hose.
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the axle (Fig. 6).
(3) Install the two brake lines at the bottom of the
hose located at the axle (Fig. 6).
(4) Install the vent tube (Fig. 6).
(5) Install the brake hose clip at the top of the
hose located at the frame (Fig. 5).
(6) Install the brake line to the hose at the frame
(Fig. 5).
(7) Lower the vehicle and remove the support.
(8) Remove the prop rod.
(9) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - REAR TUBE / HOSE
ASSEMBLY
(1) Install the hose.
(2) Install the banjo bolt at the caliper (Fig. 7).
(3) Install the mounting bolt for the brake hose at
the axle (Fig. 7).
(4) Install the brake line located at the axle.
(5) Lower the vehicle and remove the support.
(6) Remove the prop rod.
(7) Bleed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
INSTALLATION - FRONT BRAKE HOSE
(1) Install the hose.
(2) Install the mounting bolt for the brake hose at
the frame (Fig. 9).
Fig. 6 REAR HOSE
1 - BRAKE HOSE
2 - VENT HOSE
3 - BRAKE LINES
Fig. 7 BRAKE LINE WITH RUBBER HOSE
1 - BANJO BOLT
2 - MOUNTING BOLT
3 - REAR TUBE / HOSE ASSEMBLY
Fig. 8 BRAKE HOSE MOUNTED PASSENGER SIDE
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BANJO BOLT
4 - WHEEL SPEED SENSOR WIRE
DRBRAKES - BASE 5 - 9
BRAKE LINES (Continued)