2003 DODGE RAM app

INSTALLATION
(1) Slide the slip yoke onto the transmission/trans-
fer case output shaft.
(2) Align and install center bearing on crossmem-
ber, if necessary and tighten nutts to 54 N´m (40 ft.
lbs.).
(3) Align reference marks on the propeller shaft
yoke and pinion companion flange (Fig. 13).
(4) Tighten pinion companion flange bolts to 115
N´m (85 ft. lbs.).
(5) Lower the vehicle.
CENTER BEARING
REMOVAL
(1) Remove rear propeller shaft.
(2) Mark the two shafts (Fig. 14) for installation
reference.
(3) Remove slip joint boot clamp and separate the
two shafts.
(4) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(5) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during
removal of center bearing.
(6) Set shaft in press and press bearing off the
shaft.
INSTALLATION
NOTE: Two types of center bearings are used and
are not interchangeable. Install the same type as
the vehicle was built with.
(1) Install new slinger on shaft and drive into posi-
tion with appropriate installer tool.
(2) Install new center bearing on shaft with Bear-
ing Installer Tool 6052. Drive on shaft with hammer
until bearing is seated.
(3) Clean shaft splines and apply a coat of multi-
purpose grease.
(4) Align master splines and slide front and rear
half-shafts together. Reposition slip yoke boot and
install new clamp.
(5) Install propeller shaft in vehicle.
ADJUSTMENTS
CENTER BEARING
Launch shudder is a vibration that occurs at first
acceleration from a stop. Shudder vibration usually
peaks at the engines highest torque output. Shudder
is a symptom associated with vehicles using a two-
piece propeller shaft. To decrease shudder, lower the
center bearing in 1/8 inch increments. Use shim
stock or fabricated plates. Plate stock must be used
to maintain compression of the rubber insulator
around the bearing. Do not use washers. Replace the
original bolts with the appropriate increased length
bolts.
Fig. 13 REAR PROPELLER SHAFT
1 - COMPANION FLANGE
2 - PROPELLER SHAFT
Fig. 14 REFERENCE MARKS
1 - REFERENCE MARK
2 - CENTER BEARING
3 - BOOT CLAMP
4 - DUST BOOT
3 - 8 PROPELLER SHAFTDR
REAR PROPELLER SHAFT (Continued)

SINGLE CARDAN UNIVERSAL
JOINTS
DISASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 15).
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 16).(7) If the bearing cap will not pull out of the yoke
by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 17).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
ASSEMBLY
NOTE: The following procedure is described for a
propeller shaft equipped with only a cardan joint in
the tube yoke. If the propeller shaft is equipped
with a companion yoke, simply repeat the following
steps to remove the cardan joint from the compan-
ion yoke after removing the cardan joint from the
tube yoke.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to inside of yoke bores to aid in installa-
tion.
Fig. 15 Snap Ring
1 - SNAP RING
Fig. 16 Press Out Bearing
1 - PRESS
2 - SOCKET
DRPROPELLER SHAFT 3 - 9

HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION.............................11
DIAGNOSIS AND TESTING................11
REMOVAL.............................11
INSTALLATION.........................12
SPECIFICATIONS.......................12
SPECIAL TOOLS.......................12CV JOINT-OUTER
REMOVAL.............................13
INSTALLATION.........................13
CV JOINT-INNER
REMOVAL.............................16
INSTALLATION.........................16
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate.
DIAGNOSIS AND TESTING
Check for grease at the inboard and outboard C/V
joint. This is a sign of boot or boot clamp damage.
NOISE/VIBRATION IN TURNS
A clicking noise or a vibration in turns could be
caused by a damaged outer C/V or inner tripod joint
seal boot or seal boot clamps. This will result in the
loss/contamination of the joint grease, resulting in
inadequate lubrication of the joint. Noise could also
be caused by another component of the vehicle com-
ing in contact with the half shafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of a damaged or worn
C/V joint. A torn boot or loose/missing clamp on the
inner/outer joint which has allowed the grease to be
lost will damage the C/V joint.
SHUDDER/VIBRATION DURING ACCELERATION
This problem could be a result of a worn/damaged
inner tripod joint or a sticking tripod joint. Improper
wheel alignment may also cause a shudder or vibra-
tion.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of out of balance
front tires or tire/wheel runout. Foreign material
(mud, etc.) packed on the backside of the wheel(s)
will also cause a vibration.
REMOVAL
(1) Loosen lug nuts and hub nut while the with
the vehicle brakes applied.
(2) Raise and support the vehicle.
(3) Remove wheel and tire assembly
(4) Remove half shaft hub nut.
(5) Remove brake caliper and rotor.
(6) Position hydraulic jack under lower suspension
arm and raise jack to unload rebound bumper.
(7) Remove lower shock absorber bolt.
(8) Remove upper ball joint nut and seperate ball
with Remover 8677 (Fig. 1).
Fig. 1 UPPER BALL JOINT SEPARATION
1 - UPPER CONTROL ARM
2 - REMOVER
3 - STEERING KNUCKLE
DRHALF SHAFT 3 - 11

(9) Disengage inner C/V joint from the axle shaft
snap-ring by apply pressure with two pry bars
between the C/V housing and axle housing.
(10) Tilt the knuckle out and push the half shaft
out of the knuckle (Fig. 2).
CAUTION: Do not damage outer C/V threads while
removing half shaft.
(11) Remove the half shaft from the vehicle.
INSTALLATION
(1) Clean hub bearing bore, hub bearing mating
surface and half shaft splines.(2) Apply a light coating of grease to the front axle
shaft output splines.
(3) Install half shaft into the knuckle (Fig. 3).
(4) Install half shaft on the axle output shaft.
Push firmly to engage the axle output shaft snap
ring into the inner C/V housing.
(5) Install upper ball joint into the knuckle.
(6) Install upper ball joint nut and tighten to spec-
ification.
(7) Install lower shock absorber bolt and tighten to
specification.
(8) Install brake rotor and caliper.
(9) Install half shaft hub nut and tighten to 251
N´m (185 ft. lbs.).
(10) Install the wheel and tire assembly.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Half Shaft Nut 251 185 -
SPECIAL TOOLS
Fig. 2 STEERING KNUCKLE
1 - STEERING KNUCKLE
2 - SHOCK
3 - HALFSHAFT
4 - DISC BRAKE CALIPER
5 - HUB/BEARING
Fig. 3 HALF SHAFT AND HUB/BEARING
1 - HUB/BEARING MOUNTING NUTS
2 - HALF SHAFT
CLAMP INSTALLER C-4975A
3 - 12 HALF SHAFTDR
HALF SHAFT (Continued)

CV JOINT-OUTER
REMOVAL
(1) Clamp shaft in a vise (with soft jaws) and sup-
port C/V joint.
(2) Remove clamps with a cut-off wheel or grinder
(Fig. 4).
CAUTION: Do not damage C/V housing or half
shaft.
(3) Slide the boot down the shaft.
(4) Remove lubricant to expose the C/V joint snap
ring.
(5) Spread snap ring and slide the joint off the
shaft (Fig. 5).
(6) Slide boot off the shaft and discard old boot.
(7) Mark alignment marks on the inner race/hub,
bearing cage and housing with dabs of paint (Fig. 6).
(8) Clamp C/V joint in a vertical position in a soft
jawed vise.
(9) Press down one side of the bearing cage to gain
access to the ball at the opposite side.
NOTE: If joint is tight, use a hammer and brass drift
to loosen the bearing hub. Do not contact the bear-
ing cage with the drift.
(10) Remove ball from the bearing cage (Fig. 7).
(11) Repeat step above until all six balls are
removed from the bearing cage.
(12) Lift cage and inner race upward and out from
the housing (Fig. 8).
(13) Turn inner race 90É in the cage and rotate the
inner race/hub out of the cage (Fig. 9).
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint
and boot.
(1) Clean all C/V joint components and shaft.
(2) Apply a light coat of grease supplied with the
joint/boot to the C/V joint components before assem-
bling them.
(3) Align the inner race, cage and housing accord-
ing to the alignment reference marks.
(4) Insert the inner race into the cage (Fig. 10) and
rotate race into the cage.
(5) Rotate the inner race/hub in the cage (Fig. 11).
Fig. 4 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 5 OUTER C/V JOINT
1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 6 BEARING ACCESS
1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING
DRHALF SHAFT 3 - 13

(6) Insert cage into the housing (Fig. 12). Rotate
the cage 90É into the housing so the large bearing
hub counterbore is facing outwards.
(7) Apply the grease supplied with the joint/boot to
the ball races. Spread the grease equally between all
the races.
(8) Tilt inner race/hub and cage and install the
balls (Fig. 13).
(9) Place new clamps onto new boot and slide boot
onto the shaft to it's original position.
(10) Apply the rest of grease to the C/V joint and
boot.
Fig. 7 BEARING
1 - HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BALL
Fig. 8 CAGE AND INNER RACE/HUB
1 - HOUSING
2 - INNER RACE
3 - CAGE WINDOW
Fig. 9 INNER RACE/HUB
Fig. 10 INNER RACE/HUB
1 - INNER RACE/HUB
2 - BEARING CAGE
Fig. 11 CAGE AND INNER RACE/HUB
1 - CAGE WINDOWS
2 - SNAP RING
3 - 14 HALF SHAFTDR
CV JOINT-OUTER (Continued)

FRONT AXLE - C205F
TABLE OF CONTENTS
page page
FRONT AXLE - C205F
DESCRIPTION.........................18
OPERATION...........................18
DIAGNOSIS AND TESTING................18
REMOVAL.............................21
INSTALLATION.........................21
ADJUSTMENTS........................21
SPECIFICATIONS.......................29
SPECIAL TOOLS.......................30
AXLE SHAFTS
REMOVAL.............................33
INSTALLATION.........................33
AXLE SHAFT SEALS
REMOVAL.............................33
INSTALLATION.........................33
AXLE BEARINGS
REMOVAL.............................33INSTALLATION.........................34
PINION SEAL
REMOVAL.............................34
INSTALLATION.........................35
DIFFERENTIAL
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL.............................36
DISASSEMBLY.........................37
ASSEMBLY............................38
INSTALLATION.........................38
DIFFERENTIAL CASE BEARINGS
REMOVAL.............................39
INSTALLATION.........................39
PINION GEAR/RING GEAR
REMOVAL.............................40
INSTALLATION.........................42
FRONT AXLE - C205F
DESCRIPTION
The axle consists of an alumunum center section
with an axle tube extending from one side. The tube
is pressed into the differential housing. The power is
transferred from the axle through two constant veloc-
ity (C/V) drive shafts to the wheel hubs. The drive
shafts are identical and interchangeable.
OPERATION
The axle receives power from the propeller shaft.
The propeller shaft is connected to the pinion gear
which rotates the differential through the gear mesh
with the ring gear bolted to the differential case. The
engine power is transmitted to the axle shafts
through the pinion mate and side gears. The side
gears are splined to the axle shafts.
DIAGNOSIS AND TESTING
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant, incorrect backlash, tooth contact, worn/damaged
gears or the carrier housing not having the proper
offset and squareness.
Gear noise usually happens at a specific speed
range. The noise can also occur during a specific type
of driving condition. These conditions are accelera-
tion, deceleration, coast, or constant load.When road testing, first warm-up the axle fluid by
driving the vehicle at least 5 miles and then acceler-
ate the vehicle to the speed range where the noise is
the greatest. Shift out-of-gear and coast through the
peak-noise range. If the noise stops or changes
greatly:
²Check for insufficient lubricant.
²Incorrect ring gear backlash.
²Gear damage.
Differential side gears and pinions can be checked
by turning the vehicle. They usually do not cause
noise during straight-ahead driving when the gears
are unloaded. The side gears are loaded during vehi-
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This
noise changes only with vehicle speed. Pinion bearing
noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
heard during a coast, the front pinion bearing is the
source.
Worn or damaged differential bearings usually pro-
duce a low pitch noise. Differential bearing noise is
similar to pinion bearing noise. The pitch of differen-
3 - 18 FRONT AXLE - C205FDR

tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.
VIBRATION
Vibration at the rear of the vehicle is usually
caused by:
²Damaged drive shaft.
²Missing drive shaft balance weight(s).
²Worn or out of balance wheels.
²Loose wheel lug nuts.
²Worn U-joint(s).
²Loose/broken springs.
²Damaged axle shaft bearing(s).
²Loose pinion gear nut.
²Excessive pinion yoke run out.
²Bent axle shaft(s).Check for loose or damaged front end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear end
vibration. Do not overlook engine accessories, brack-
ets and drive belts.
All driveline components should be examined
before starting any repair.
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING)
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged) can be caused by:
²High engine idle speed.
²Transmission shift operation.
²Loose engine/transmission/transfer case mounts.
²Worn U-joints.
²Loose spring mounts.
²Loose pinion gear nut and yoke.
²Excessive ring gear backlash.
²Excessive side gear to case clearance.
The source of a snap or a clunk noise can be deter-
mined with the assistance of a helper. Raise the vehi-
cle on a hoist with the wheels free to rotate. Instruct
the helper to shift the transmission into gear. Listen
for the noise, a mechanics stethoscope is helpful in
isolating the source of a noise.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.7. Inspect and replace as
necessary.
DRFRONT AXLE - C205F 3 - 19
FRONT AXLE - C205F (Continued)