2003 DODGE RAM Service Repair Manual

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Page 209 of 2895

DODGE RAM 2003 Service Repair Manual ADJUSTER WRENCH 8883
PINION BLOCK 8897
FLANGE PULLER 8992
FLANGE WRENCH 8979
PINION DRIVER 8977
PINION INSTALLER 8981
SOCKET 8954
BEARING INSTALLER 8965
3 - 136 REAR AXLE - 11 1/2 AADR
REAR AXLE - 11

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DODGE RAM 2003 Service Repair Manual BEARING INSTALLER D-389
CUP INSTALLER 8153
CUP INSTALLER 8960
CUP INSTALLER 8961
CUP INSTALLER 8968
SEAL INSTALLER 8896
SEAL INSTALLER 8963
DRREAR AXLE - 11 1/2 AA 3 - 137
REAR AXLE - 11 1/2 AA (Conti

Page 211 of 2895

DODGE RAM 2003 Service Repair Manual AXLE SHAFTS
REMOVAL
(1) Remove axle shaft flange bolts (Fig. 15).
(2) Slide axle shaft out of the axle tube.
(3) Remove axle shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use

Page 212 of 2895

DODGE RAM 2003 Service Repair Manual NOTE: The inner part of the seal may stay on the
axle tube (Fig. 18). This part must also be removed.
(7) Remove rear bearing.
(8) Remove hub bearing cups with a hammer and
drift.
INSTALLATION
(1) Ins

Page 213 of 2895

DODGE RAM 2003 Service Repair Manual (7) Back off nut about 30É and align next hub nut
key slot with axle tube key slot and install locking
key.
NOTE: End play should be 0.025-0.25 mm
(0.01-0.001 in.)
(8) Install retainer ring with ring

Page 214 of 2895

DODGE RAM 2003 Service Repair Manual ments, until pinion rotating torque is 0.40-0.57 N´m
(3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shaft

ments, until pinion rotating torque is 0.40-0.57 N´m
(3-5 in. lbs.) greater than recorded measurement.
(8) Rotate pinion several times then verify pinion
rotating torque again.
(9) Install axle shafts.
(10) Install propeller shaft with reference marks
aligned.
(11) Check differential fluid level.
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. 25).
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.
26). 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.
Fig. 23 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 24 FLANGE WRENCH
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 25 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
Fig. 26 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
DRREAR AXLE - 11 1/2 AA 3 - 141
PINION SEAL (Continued)

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DODGE RAM 2003 Service Repair Manual REMOVAL
(1) Remove fill hole plug from the differential
housing cover.
(2) Remove differential housing cover and drain
the lubricant.
(3) Remove axle shafts.
(4) Remove adjuster lock bolts and adjuste

Page 216 of 2895

DODGE RAM 2003 Service Repair Manual (4) Rotate the other pinion gear with thrust
washer (Fig. 31) to the differential window and
remove the gear.
(5) Remove differential side gears and thrust
washers (Fig. 32).ASSEMBLY
NOTE: If the same

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