2003 DODGE RAM Front differential

(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-4171 (Fig. 30).
(3) Install anewaxle shaft seal with Installer
8694 and Handle C-4171.
(4) Lubricate seal lip with gear lubricant.
(5) 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.(6) Install axle shaft O-ring.
(7) Check the differential fluid level and add fluid
if necessary.
(8) Install skid plate, if necessary.
(9) Install half shaft.
PINION SEAL
REMOVAL
(1) Remove skid plate, if equipped.
(2) Remove both half shafts.
(3) Mark the propeller shaft and pinion companion
flange (Fig. 31) for installation reference.
(4) Remove the front propeller shaft.
(5) Rotate the pinion gear three or four times and
verify pinion rotates smoothly.
(6) Record pinion rotating torque with an inch
pound torque wrench, for installation reference (Fig.
32).
(7) Position Holder 6719 against the companion
flange and install a four bolts and washers into the
threaded holes and tighten the bolts.
(8) Remove the pinion nut.
(9) Remove the companion flange with Remover
C-452 (Fig. 33).
(10) Remove pinion seal with a pry tool or a slide
hammer mounted screw.
Fig. 29 BEARING REMOVER CUP
1 - REMOVER CUP
2 - BEARING
3 - NUT
Fig. 30 BEARING INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 31 COMPANION FLANGE
1 - COMPANION FLANGE
2 - PROPELLER SHAFT
3 - FLANGE YOKE
4 - REFERENCE MARK
3 - 34 FRONT AXLE - C205FDR
AXLE BEARINGS (Continued)

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
Installer C-3718 and Holder 6719A.(4) Position holder against the companion flange
and install four bolts and washers into the threaded
holes. Tighten the bolt and washer so that the holder
is held to the flange.
(5) Install anewpinion nut onto the pinion shaft
and tighten the pinion nut until there is zero bearing
end-play (Fig. 35).
CAUTION: Do not exceed 271 N´m (200 ft. lbs.) the
minimum tightening torque when installing the
companion flange at this point. Damage to the col-
lapsible spacer or bearings may result.
Fig. 32 PINION ROTATING TORQUE
1 - COMPANION FLANGE
2 - INCH POUND TORQUE WRENCH
Fig. 33 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 COMPANION FLANGE HOLDER
1 - DIFFERENTIAL HOUSING
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
DRFRONT AXLE - C205F 3 - 35
PINION SEAL (Continued)

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)

(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 new marks for later reference.
(4) Install Adapter Plates 8142-A onto the housing.
(5) Install Spreader W-129-B onto the adapter
plates (Fig. 39) and tighten the turnbuckle finger-
tight.(6) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing and zero the indicator.
(7) Spread the housing to remove the differential
case from the housing (Fig. 40). 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.
(8) Remove dial indicator.
(9) While holding the differential case in position,
remove bearing cap bolts and caps.
(10) Remove differential from the housing (Fig.
41). Ensure differential bearing cups and shims
remain in position on the differential bearings.
(11) Tag differential bearing cups and shims to
indicate their location.
(12) Remove spreader from housing.
DISASSEMBLY
(1) Remove ring gear.
(2) Remove roll-pin holding mate shaft in housing.
(3) Remove pinion gear mate shaft.
(4) Rotate differential side gears and remove the
pinion mate gears and thrust washers (Fig. 42).
(5) Remove the differential side gears and thrust
washers.
Fig. 38 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 39 ADAPTER PLATES AND SPREADER
1 - ADAPTER PLATE
2 - SPREADER
Fig. 40 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - SPREADER
DRFRONT AXLE - C205F 3 - 37
DIFFERENTIAL (Continued)

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 shaft
with the hole in the differential case.
(5) Install the roll-pin in the differential case a
punch and hammer (Fig. 43). Peen the edge of the
roll-pin hole in the differential case in two places
180É apart.
(6) Lubricate all differential components with
hypoid gear lubricant.
(7) Install ring gear.
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) Install Spreader W-129-B with the Adapter
Plates 8142-A and install the safety holddown
clamps. Tighten the tool turnbuckle finger-tight.
(2) Install a Pilot Stud L-4438 at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load indicator plunger against the
opposite side of the housing and zero the indicator.
Fig. 41 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 42 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 43 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
3 - 38 FRONT AXLE - C205FDR
DIFFERENTIAL (Continued)

(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 indicator.
(5) Install differential case in the housing. Ensure
differential bearing cups remain in position on the
bearings and the differential preload shims are
seated in the housing. Tap differential case to ensure
bearings cups are seated in the housing.
(6) Install bearing caps to their original locations
and loosely install cap bolts.
(7) Remove housing spreader.
(8) Tighten the bearing cap bolts to 61 N´m (45 ft.
lbs.).
(9) Install axle shafts.
(10) Apply a bead of red Mopar Silicone Sealant or
equivalent to the housing cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(11) Install cover and tighten bolts in a criss-cross
pattern to 22 N´m (15 ft. lbs.).
(12) Fill differential with lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential from housing.
(2) Remove bearings from the differential case
with Puller/Press C-293-PA, Adapters C-293-48 and
Plug C-293-3 (Fig. 44).
INSTALLATION
(1) Install differential case bearings with Installer
C-3716-A and Handle C-4171 (Fig. 45).
(2) Install differential into the housing.
Fig. 44 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
Fig. 45 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
DRFRONT AXLE - C205F 3 - 39
DIFFERENTIAL (Continued)

PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(1) Remove differential from housing.
(2) Place differential case in a vise with soft jaw
(Fig. 46).
(3) Remove bolts holding ring gear to differential
case.
(4) Drive ring gear from differential case with a
soft hammer (Fig. 46).
(5) Mark the companion yoke and companion
flange for installation reference.
(6) Remove companion flange bolts and tie the pro-
peller shaft to the vehicle underbody.
(7) Rotate companion flange three or four times
and verify flange rotates smoothly.
(8) Record pinion rotating torque an inch pound
torque wrench for installation reference (Fig. 47).
(9) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(10) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so that
the Holder 6719 is held to the flange.
(11) Remove the pinion nut.
(12) Remove the companion flange with Remover
C-452 (Fig. 48).
(13) Remove pinion from differential housing.
(14) Remove pinion seal with a pry tool or a slide
hammer mounted screw.(15) Remove oil slinger, if equipped and front pin-
ion bearing.
(16) Remove front pinion bearing cup with
Remover 8831 and Handle C-4171 (Fig. 49).
(17) Remove rear pinion bearing cup from housing
(Fig. 50) with Remover 8401 and Handle C-4171.
Fig. 46 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 47 PINION ROTATING TORQUE
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 48 COMPANION FLANGE REMOVER
1 - COMPANION FLANGE
2 - PULLER TOOL
3 - 40 FRONT AXLE - C205FDR

(7) Place pinion depth shim (Fig. 56) on the pinion
shaft.
(8) Install rear pinion bearing onto the pinion
shaft with Installer 6448 and a press (Fig. 57).(9) Installnewcollapsible spacer onto the pinion
shaft (Fig. 58).
(10) Lubricate rear pinion bearing and install the
pinion gear in the housing.
(11) Install companion flange with Installer
C-3718 and Holder 6719.
(12) Installnewpinion nut and tighten to 271
N´m (200 ft. lbs.) (Fig. 59).
(13) Using Holder 6719 and a torque wrench set at
475 N´m (350 ft. lbs.). Tighten pinion nut until bear-
ing end play is taken up.
(14) Slowly tighten the nut in 6.8 N´m (5 ft. lbs.)
increments until desired rotating torque is achieved.
Measure rotating torque frequently to avoid over-
crushing the collapsible spacer (Fig. 60). The pinion
rotating torque should be:
²Original Bearings: 1 to 2.5 N´m (10 to 20 in.
lbs.)
²New Bearings: 2.0 to 2.8 N´m (18 to 25 in. lbs.)
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.
(15) Invert differential case and start two ring
gear bolts to provide ring gear bolt hole alignment.
(16) Invert differential case in the vise.
Fig. 56 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 57 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - REAR PINION BEARING
Fig. 58 COLLAPSIBLE SPACER
1 - COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
DRFRONT AXLE - C205F 3 - 43
PINION GEAR/RING GEAR (Continued)