2003 DODGE RAM service

(friction modifier) should be added after repair ser-
vice or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 37).
(6) If rotating torque is less than 41 N´m (30 ft.
lbs.) or more than 271 N´m (200 ft. lbs.) on either
wheel the unit should be serviced.
DISASSEMBLY
(1) Clamp Fixture 6965 in a vise and position the
differential case on the fixture (Fig. 38).
(2) Remove ring gear if the ring gear is to be
replaced.
(3) Remove pinion gear mate shaft lock screw.
(4) Remove pinion gear mate shaft with a drift and
hammer.(5) Install and lubricate Step Plate C-6960-3 (Fig.
39).
(6) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
Fig. 37 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 38 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 39 STEP PLATE
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - DISC
3 - 90 REAR AXLE-91/4DR
DIFFERENTIAL-TRAC-LOK (Continued)

INSTALLATION
(1) Install differential side bearings with Installer
C-4213 and Handle C-4171 (Fig. 49).
(2) Install differential case into housing.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one gear without replac-
ing the other matching gear.
(1) Mark companion flange and propeller shaft for
installation reference.
(2) Disconnect propeller shaft from the companion
flange and tie propeller shaft to underbody.
(3) Remove axle shafts.
(4) Remove differential from the differential hous-
ing.
(5) Place differential case in a vise with soft metal
jaw protectors..
(6) Remove ring gear bolts from the differential
case.
(7) Drive ring gear off the differential case with a
rawhide hammer (Fig. 50).(8) Install bolts into two of the threaded holes in
the companion flange 180É apart.
(9) Position Holder 6719 against the companion
flange and install a bolt and washer into one of the
remaining threaded holes. Tighten the bolts so the
Holder 6719 is held to the flange.
(10) Use Holder 6719 to hold companion flange
and remove the companion flange nut and washer.
(11) Remove companion flange with Remover
C-452 (Fig. 51).
(12) Remove pinion gear from the housing (Fig.
52).
Fig. 49 DIFFERENTIAL CASE BEARING
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 50 RING GEAR
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
Fig. 51 COMPANION FLANGE
1 - COMPANION FLANGE
2 - REMOVER
3 - 94 REAR AXLE-91/4DR
DIFFERENTIAL CASE BEARINGS (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)

Condition Possible Causes Correction
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
3 - 102 REAR AXLE - 10 1/2 AADR
REAR AXLE - 10 1/2 AA (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from axle housing.
(4) Place differential on Plug 8888 and drive
exciter ring off the differential case with a hammer
and punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
(5) Place differential case in a vise with soft metal
jaw protectors
(6) Remove bolts holding ring gear to differential
case.(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flnage nut and washer.
(9) Remove pinion flange from the pinion with Pin-
ion Flange Puller 8992 (Fig. 52).
(10) Remove pinion gear from housing, with Pinion
Driver 8977 (Fig. 53) and a hammer.
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
Fig. 50 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 51 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
3 - 122 REAR AXLE - 10 1/2 AADR

Condition Possible Causes Correction
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
differential bearings.1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
3. Excessive spinning of one
wheel/tire.3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
DRREAR AXLE - 11 1/2 AA 3 - 129
REAR AXLE - 11 1/2 AA (Continued)

PINION GEAR/RING GEAR/
TONE RING
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pinion flange and propeller shaft for
installation alignment.
(2) Disconnect propeller shaft from pinion flange
and remove propeller shaft.
(3) Remove differential from the housing.
(4) Place differential on Plug 8964. Drive exciter
ring off the differential case with a hammer and
punch (Fig. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
(5) Place differential case in a vise with soft metal
jaw protectors(6) Remove bolts holding ring gear to differential
case.
(7) Drive ring gear from differential case with a
soft hammer (Fig. 50).
(8) Hold pinion flange with Flange Wrench 8979
(Fig. 51) and remove pinion flange nut.
Fig. 49 EXCITER RING
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
Fig. 50 RING GEAR
1 - DIFFERENTIAL CASE
2 - RING GEAR
3 - HAMMER
Fig. 51 FLANGE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
DRREAR AXLE - 11 1/2 AA 3 - 149

FLUID RESERVOIR
REMOVAL
(1) Install the prop rod on the brake pedal to keep
pressure on the brake system.
(2) Remove the reservoir cap and siphon fluid into
a drain container (Fig. 34).
(3) Remove the electrical connector from the fluid
level switch in the reservoir (Fig. 34).
(4) Remove the reservoir mounting bolt (Fig. 34).
(5) Remove the reservoir from the master cylinder
by pulling upwards.
(6) Remove old grommets from cylinder body (Fig.
34).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubricate the new grommets with clean brake
fluid and Install new grommets in cylinder body. Use
finger pressure to install and seat grommets.
(2) Start the reservoir in grommets. Then rock the
reservoir back and forth while pressing downward to
seat it into the grommets.
(3) Install the mounting bolt for the reservoir to
the master cylinder.
(4) Reconnect the electrical connector to the fluid
reservoir level switch.
(5) Remove the prop rod from the vehicle.(6) Fill and bleed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE JUNCTION BLOCK
REMOVAL
(1) Remove the brake lines from the junction block
(Fig. 35).
(2) Remove the junction block mounting bolt and
remove the junction block from the bracket (Fig. 35).
INSTALLATION
(1) Position the junction block on the bracket and
install the mounting bolt. Tighten the mounting bolt
to 23 N´m (210 in. lbs.) (Fig. 35).
(2) Install the brake lines into the junction block
and tighten to 19-23 N´m (170-200 in. lbs.) (Fig. 35).
(3) Bleed the base brake system, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL - STAN-
DARD PROCEDURE).
MASTER CYLINDER
DESCRIPTION
A two-piece master cylinder is used on all models.
The cylinder body containing the primary and sec-
ondary pistons is made of aluminum. The removable
fluid reservoir is made of nylon reinforced with glass
fiber. The reservoir stores reserve brake fluid for the
hydraulic brake circuits and has a switch for indicat-
ing low fluid levels. The reservoir is the only service-
able component.
The fluid compartments of the nylon reservoir are
interconnected to permit fluid level equalization.
However, the equalization feature does not affect cir-
Fig. 34 FLUID RESERVOIR
1 - MASTER CYLINDER CAP
2 - FLUID RESERVOIR
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - MOUNTING BOLT
6 - GROMMETS
Fig. 35 JUNCTION BLOCK
1 - BRAKE LINES
2 - JUNCTION BLOCK
DRBRAKES - BASE 5 - 19