2003 DODGE RAM light

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-
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 a:
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 rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
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.
1 - HUB
2 - AXLE SHAFT
3 - VENT FITTING
4 - DIFFERENTIAL HOUSING
5 - CUP
6 - FRONT PINION BEARING CONE
7 - NUT
8 - WASHER
9 - COMPANION FLANGE
10 - SEAL
11 - AXLE SHAFT
12 - HUB
13 - STUD
14 - BEARING CUP
15 - REAR PINION BEARING CONE
16 - DIFFERENTIAL BEARING
17 - ADJUSTER
18 - LOCK
19 - BOLT
20 - BEARING CAP
21 - CAP BOLT
22 - BEARING CUP
23 - THRUST WASHER
24 - SIDE GEAR
25 - C-LOCK
26 - DIFFERENTIAL POSITIONS
27 - THRUST WASHER
28 - COVER29 - PLUG
30 - COVER BOLT
31 - WASHER
32 - CLIP
33 - SIDE GEAR
34 - THRUST WASHER
35 - DIFFERENTIAL BEARING CONE
36 - C-LOCK
37 - BOLT
38 - LOCK
39 - BEARING CUP
40 - ADJUSTER
41 - BEARING CUP
42 - BOLT
43 - PINION MATE SHAFT
44 - EXCITER RING
45 - DIFFERENTIAL CASE
46 - RING GEAR BOLT
47 - RING GEAR
48 - PINION
49 - PINION GEAR DEPTH SHIM
50 - PRELOAD COLLAPSIBLE SPACER
51 - SEAL
52 - AXLE SHAFT BEARING
53 - AXLE SHAFT TUBE
54 - AXLE TUBE
55 - AXLE SHAFT BEARING
56 - SEAL
DRREAR AXLE - 9 1/4 3 - 71
REAR AXLE - 9 1/4 (Continued)

(3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
measurements will be taken with the same gear
teeth meshed.
(4) Loosen the right-side, tighten the left-side
threaded adjuster. Obtain backlash of 0.076 to 0.102
mm (0.003-0.004 in.) with each adjuster tightened to
14 N´m (10 ft. lbs.). Seat the bearing cups with the
procedure described above.
(5) Tighten the differential bearing cap bolts 136
N´m (100 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N´m (75 ft. lbs.). Seat the bearing cups with the pro-
cedure described above. Continue to tighten the
right-side adjuster and seat bearing cups until the
torque remains constant at 102 N´m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).
(8) Continue increasing the torque at the right-
side threaded adjuster until the specified backlash is
obtained.
NOTE: The left-side threaded adjuster torque
should have approximately 102 N´m (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Tighten the left-side threaded adjuster until
102 N´m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(10) Install the threaded adjuster locks and
tighten the lock screws to 10 N´m (90 in. lbs.).GEAR CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:
²Gear contact pattern is correct (Fig. 9). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig.
10). Decrease backlash, by moving the ring closer to
the pinion gear using the adjusters.
Fig. 8 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
Fig. 9 CORRECT CONTACT PATTERN
Fig. 10 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
DRREAR AXLE - 9 1/4 3 - 77
REAR AXLE - 9 1/4 (Continued)

(3) Coat the lip of thenewaxle seal with axle
lubricant and install with Installer C-4076-B and
Handle C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
(4) Install the axle shaft.
(5) Install differential cover and fill with gear
lubricant to the bottom of the fill plug hole.
PINION SEAL
REMOVAL
(1) Mark universal joint, companion flange and
pinion shaft for installation reference.
(2) Remove propeller shaft from the companion
flange.
(3) Remove the brake rotors to prevent any drag.
(4) Rotate companion flange three or four times
and record pinion rotating torque with an inch pound
torque wrench.
(5) Install two bolts into the companion flange
threaded holes, 180É apart. Position Holder 6719A
against the companion flange and install and tighten
two bolts and washers into the remaining holes.
(6) Hold the companion flange with Holder 6719A
and remove pinion nut and washer.
(7) Remove companion flange with Remover C-452
(Fig. 24).(8) Remove pinion seal with pry tool or slide-ham-
mer mounted screw.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal.
(2) Installnewpinion seal with Installer C-3860-A
and Handle C-4171 (Fig. 25)
(3) Install companion flange on the end of the
shaft with the reference marks aligned.
(4) Install two bolts into the threaded holes in the
companion flange, 180É apart.
(5) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so holder
is held to the flange.
(6) Install companion flange on pinion shaft with
Installer C-3718 and Holder 6719.
(7) Install pinion washer and anewpinion nut.
The convex side of the washer must face outward.
CAUTION: Never exceed the minimum tightening
torque 285 N´m (210 ft. lbs.) when installing the
companion flange retaining nut at this point. Dam-
age to collapsible spacer or bearings may result.
(8) Hold companion flange with Holder 6719 and
tighten the pinion nut with a torque set to 285 N´m
(210 ft. lbs.) (Fig. 26). Rotate pinion several revolu-
tions to ensure the bearing rollers are seated.
(9) Rotate pinion with an inch pound torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N´m (5 in. lbs.) (Fig. 27).
Fig. 24 COMPANION FLANGE
1 - COMPANION FLANGE
2 - PULLER
Fig. 25 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
3 - HOUSING
DRREAR AXLE - 9 1/4 3 - 85
AXLE BEARINGS (Continued)

(2) Remove differential cover and drain the lubri-
cant.
(3) Clean housing cavity with flushing oil, light
engine oil or a lint free cloth.
NOTE: Do not use steam, kerosene or gasoline to
clean the housing.
(4) Remove axle shafts.
(5) Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark differential housing and bearing caps for
installation reference (Fig. 30).(7) Remove bearing threaded adjuster lock from
each bearing cap.
(8) Loosen differential bearing cap bolts.
(9) Loosen differential bearing adjusters through
the axle tubes with Wrench C-4164 (Fig. 31).
(10) Hold differential case while removing bearing
caps and adjusters.
(11) Remove differential case.
NOTE: Tag the differential bearing cups and
threaded adjusters to indicate their location.
Fig. 28 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. 29 DIFFERENTIAL-ON TURNS
1 - PINION GEARS ROTATE ON PINION SHAFT
Fig. 30 REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARK
3 - BEARING CAPS
Fig. 31 THREADED ADJUSTER TOOL
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
DRREAR AXLE - 9 1/4 3 - 87
DIFFERENTIAL (Continued)

(6) Install lubricated Step Plate C-6960-3 in lower
side gear.
(7) Install upper side gear and clutch disc pack
(Fig. 47).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in side gears and verify
pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-6960-2 until
pinion mate shaft holes in pinion gears align with
holes in case.
NOTE: If necessary, slightly tighten the forcing
screw in order to install the pinion gears.
(12) Tighten forcing screw to 122 N´m (90 ft. lbs.)
maximum to compress the Belleville springs.
(13) Lubricate and install thrust washers behind
pinion gears and align washers with a small screw
driver. Insert mate shaft into each pinion gear to ver-
ify alignment.(14) Remove forcing screw, step plate and threaded
adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove differential case from axle housing.
(2) Remove differential bearings from the case
with Puller/Press C-293-PA and Adapters C-293-47
and Plug C-293-3 (Fig. 48).
Fig. 47 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
2 - DIFFERENTIAL CASE
3 - LOWER DISC
Fig. 48 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
DRREAR AXLE - 9 1/4 3 - 93
DIFFERENTIAL-TRAC-LOK (Continued)

(18) Remove rear pinion bearing (Fig. 56) from the
pinion shaft with Puller C-293-PA and Adapters
C-293-37.
(19) Remove pinion depth shim (Fig. 57) from the
pinion shaft and record shim thickness.INSTALLATION
NOTE: The ring gear and pinion are serviced in a
matched set. Do not replace one gear without
replacing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer to Adjust-
ments for Pinion Gear Depth Setting.
(1) Apply Mopar Door Ease or equivalent stick
lubricant to outside surface of the pinion bearing
cups.
(2) Install rear pinion bearing cup (Fig. 58) with
Installer C-4308 and Driver Handle C-4171 and ver-
ify cup is seated.
(3) Install front pinion bearing cup (Fig. 59) with
Installer D-129 and Handle C-4171 and verify cup is
seated.
(4) Lubricate and install front pinion bearing into
the housing.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-4076-B
and Handle C-4735-1 (Fig. 60).
Fig. 56 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
Fig. 57 PINION DEPTH SHIM
1 - PINION DEPTH SHIM
2 - PINION GEAR
Fig. 58 REAR PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
3 - 96 REAR AXLE-91/4DR
PINION GEAR/RING GEAR/TONE RING (Continued)

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-
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 a:
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 rearend vibra-
tion. Do not overlook engine accessories, brackets
and drive belts.
NOTE: All driveline components should be exam-
ined before starting any repair.
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.
DRREAR AXLE - 10 1/2 AA 3 - 101
REAR AXLE - 10 1/2 AA (Continued)

(12) Tighten bearing cap bolts to 115 N´m (85 ft.
lbs.).
(13) Tighten adjuster lock bolts to 33 N´m (24 ft.
lbs.).
(14) Measure ring gear backlash with a Dial Indi-
cator C-3339 and Dial Indicator Stud L-4438 at eight
points around the drive side of the ring gear (Fig. 7).
The backlash should be 0.08-0.25 mm (0.003-0.010
in) with a preferred backlash of 0.13-0.18 mm (0.005-
0.007 in).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.
GEAR TOOTH CONTACT PATTERN
Gear tooth contact pattern is used to verify the cor-
rect running position of the ring and pinion gears.
This will produce low noise and long gear life. Gears
which are not positioned properly may be noisy and
have shorten gear life.
(1) Wipe clean each tooth of the ring gear.
(2) Apply gear marking compound to all of the ring
gear teeth.
(3) Verify bearing cap bolts are torque specifica-
tion.
(4) Apply parking brakes lightly to create at 14
N´m (10 ft. lbs.) pinion rotating torque.
(5) Rotate the pinion/pinion yoke 4 full revolutions
in each directions.
(6) Read gear tooth contact pattern:²Gear contact pattern correct (Fig. 8). Backlash
and pinion depth is correct.
²Ring gear too far away from pinion gear (Fig. 9).
Decrease the backlash, by moving the ring closer to
the pinion gear using the adjusters.
²Ring gear too close to pinion gear (Fig. 10).
Increase the backlash, by moving the ring away from
the pinion gear using the adjusters.
Fig. 7 RING GEAR BACKLASH
1 - DIAL INDICATOR
2 - RING GEAR
Fig. 8 CORRECT CONTACT PATTERN
Fig. 9 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
Fig. 10 INCORRECT BACKLASH
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
3 - 106 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)