2003 DODGE RAM tow

(5) Use the pry bar to spread apart the leaf (Fig.
6). The clearance between the leaves should be
enough to remove the old liner (if necessary) and
install the replacement liner.
(6) If necessary, remove the old spring tip liner
(Fig. 7).
INSTALLATION
(1) With the prybar still inserted between the
leaves, install a new spring tip liner onto the leaf.
(2) Firmly seat the spring tip liner onto the leaf. A
C-Clamp can be used to compress the adjacent leaves
together (Fig. 8) which will seat the liner retaining
pin into the hole.NOTE: THE SPRING TIP LINER IS PROPERLY
INSTALLED WHEN THE RETAINING PIN IS POINT-
ING TOWARD THE PAVEMENT AND THE WEAR PAD
IS CONTACTING THE LEAF SPRING.
(3) Apply a small amount of lubricant oil onto the
tip liner wear pad.
(4) Install all the spring tip liners.
(5) Place one spring clinch clip isolator onto the
outboard side of the spring clinch clip (Fig. 9) and
one isolator on the inboard side of the spring clinch
clip.
Fig. 6 SPRING SEPARATION
1 - REAR LEAF SPRING
2-PRYBAR
Fig. 7 SPRING TIP LINER REMOVAL
1 - SPRING TIP LINER
2 - RUBBER MALLET
Fig. 8 CLINCH CLIP
1 - C-CLAMP
2 - SPRING CLINCH CLAMP
Fig. 9 CLINCH CLIP ISOLATOR
1 - SPRING CLINCH CLIP ISOLATOR
2 - C-CLAMP
2 - 42 REARDR
SPRING TIP INSERTS (Continued)

(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) Push and hold differential case to ring gear
side of the housing.
(22) Record dial indicator reading.
(23) Subtract 0.05 mm (0.002 in.) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. Add the resulting measure-
ment to the thickness of the single dummy shim.
This is the thickness of shim required to achieve
proper backlash.
(24) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
housing.
(25) Rotate dial indicator out of the way on pilot
stud.
(26) Remove differential case, dummy bearings
and dummy shim from the housing.
(27) Install new side bearing cones and cups on
differential case.
(28) Install Spreader W-129-B and Adapter Plates
8142-A on the housing and spread open enough to
receive differential case.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(29) Place the side bearing shims in the differen-
tial housing against the housing shoulder.
(30) Install the differential case in the housing.
(31) Rotate the differential case several times to
seat the side bearings.
(32) Position the dial indicator plunger against a
ring gear tooth (Fig. 18).
(33) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
Fig. 16 ZERO DIAL INDICATOR
1 - PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
Fig. 17 RECORD DIAL INDICATOR
1 - DIAL INDICATOR
2 - HOUSING
3 - RING GEAR SIDE
Fig. 18 RING GEAR BACKLASH
1 - RING GEAR
2 - DIAL INDICATOR
DRFRONT AXLE - C205F 3 - 27
FRONT AXLE - C205F (Continued)

NOTE: Arbor should rotate freely in the arbor disc.
(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. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench8883 until they make contact with the differential
bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
Fig. 3 GAUGE TOOLS IN HOUSING
1. PINION HEIGHT BLOCK
2. PINION BLOCK
3. ARBOR
4. ARBOR DISCS
Fig. 4 PINION DEPTH MEASUREMENT
1. DIAL INDICATOR
2. ARBOR
3. SCOOTER BLOCK
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
3 - 50 FRONT AXLE - 9 1/4 AADR
FRONT AXLE - 9 1/4 AA (Continued)

ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their orignial locations.
(1) Lubricate all differential components with axle
lubricant.
(2) Install differential side gears and thrust wash-
ers (Fig. 36).
(3) Rotate the one pinion gear with thrust washer
into the differential case (Fig. 37). Then rotate the
other pinion gear with thrust washer into the differ-
ential case.(4) Align hole in the pinion gears with hole in the
differential case.
(5) Install pinion shaft.
(6) Installnewpinion shaft lock bolt and tighten
to 52 N´m (38 ft. lbs.).
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
(4) Install bearing caps and bolts (Fig. 38). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
Fig. 36 SIDE GEARS
1 - DIFFERENTIAL WINDOW
2 - SIDE GEAR
Fig. 37 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEARS
3 - PINION GEAR
Fig. 38 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTER
DRFRONT AXLE - 9 1/4 AA 3 - 63
DIFFERENTIAL (Continued)

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 (Fig. 6) until they make contact with the differ-
ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
Fig. 4 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 6 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
DRREAR AXLE - 10 1/2 AA 3 - 105
REAR AXLE - 10 1/2 AA (Continued)

(4) Install the other pinion gear and thrust
washer. Rotate the gears to align hole in the pinion
gears with hole in the differential case.
(5) Slide pinion shaft into the case and through
the pinion gears. Tap the shaft to seat the pinion
shaft snap-ring into the case (Fig. 35).
INSTALLATION
(1) Clean the housing cavity with a flushing oil,
light engine oil or lint free cloth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubricate differential case bearing.
(3) Install differential case with bearings cups into
the housing.
NOTE: A light coat of grease on the cups will hold
them in place during installation.
(4) Install bearing caps and bolts (Fig. 36). Tighten
the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
(5) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(6) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.
(7) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
Fig. 34 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - SIDE GEARS
3 - PINION GEAR
Fig. 35 PINION SHAFT INSTALLATION
1 - PINION SHAFT SNAP-RING
2 - SIDE GEAR
3 - PINION GEAR
4 - PINION SHAFT
Fig. 36 CASE BEARING CAP
1 - DIFFERENTIAL HOUSING
2 - BEARING CAP
3 - ADJUSTER
DRREAR AXLE - 10 1/2 AA 3 - 117
DIFFERENTIAL (Continued)

(8) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(9) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(10) Rotate the pinion several times to seat the dif-
ferential bearings.
(11) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup.
(12) Tighten pinion gear side adjuster until it just
makes contact with the bearing cup.
(13) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings6 Adjuster Holes
²Original Bearings4 Adjuster Holes
(14) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
(15) Tighten bearing cap bolts to 165 N´m (122 ft.
lbs.).
(16) Tighten adjuster lock bolts to 25 N´m (18 ft.
lbs.) (Fig. 37).
(17) Measure ring gear backlash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) Install axle shafts.
(19) Install differential housing gasket and cover.
Tighten cover bolts to 40 N´m (30 ft. lbs.).
(20) Fill axle with lubricant, refer to Lubrication &
Maintenance for capacity and lubricant type.
(21) Install fill plug and tighten to 32 N´m (24 ft.
lbs.).DIFFERENTIAL TRAC-RITE
DESCRIPTION
The Trac-RiteŸ differential is a helical gear differ-
ential. The differential has two side gears, six pinion
gears and six pinion brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begins to spin the pinion gears on
that side are forced toward the pinion brake shoes.
The pinion brake shoes then cause frictional drag on
the opposite pinion gears and the side gear. These
friction forces transfer the power to the opposite
wheel. Once the frictional forces are overcome, differ-
entiation will occur. The torque will be continually
biased by the frictional forces to the high traction
wheel.
DISASSEMBLY
(1) Remove differential ring gear bolts.
(2) Remove differential case cover locating screws
(Fig. 38).
(3) Remove differential case cover.
(4) Remove side gear and thrust washer (Fig. 39).
Fig. 37 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 38 LOCATION SCREWS
1 - DIFFERENTIAL COVER
2 - LOCATION SCREWS
3 - 118 REAR AXLE - 10 1/2 AADR
DIFFERENTIAL (Continued)

(8) Slowly slide the scooter block across the pinion
height block over to the arbor (Fig. 4). Move the
scooter block till dial indicator crests the arbor, then
record the highest reading.
(9) Select a shim equal to the dial indicator read-
ing.
(10) Install the select shim between the rear pin-
ion bearing and the pinion gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backlash is adjusted by moving the adjusters in
and out or both. By moving the adjusters the case/
ring gear will move closer or further away from the
pinion. In most cases this adjustment can be used to
achieve the correct gear tooth pattern and set the
case bearing preload.
(1) Remove adjuster lock bolts and adjuster locks
(Fig. 5).
(2) Loosen the differential bearing caps.
(3) Slide differential case toward the pinion gear
until the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
(4) Holding the differential case toward the pinion
gear, turn bearing adjusters with Spanner Wrench
8883 (Fig. 6) until they make contact with the differ-
ential bearings/cups.
(5) Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
(6) Install ring gear side adjuster lock and bolt. Do
not tighten adjuster lock bolt at this time.
(7) Tighten pinion gear side adjuster firmly
against the differential case bearing cup.
(8) Rotate the pinion several times to seat the def-
erential bearings.(9) Loosen pinion gear side adjuster until it is no
longer in contact with the bearing cup, then tighten
it until it makes contact.
(10) Tighten pinion gear side adjuster an addi-
tional:
²New Bearings:6 Adjuster Holes
²Original Bearings:4 Adjuster Holes
(11) Install pinion gear side adjuster lock and bolt.
Do not tighten adjuster lock bolt at this time.
Fig. 4 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 5 ADJUSTER LOCK BOLT
1 - DIFFERENTIAL CASE
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
Fig. 6 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
3 - 132 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11 1/2 AA (Continued)