Index Dodge Dodge Ram Truck 1500-2500-3500 - service repair manual 2005 year

Content .. 126 127 128 129 ..

Dodge Ram Truck 1500-2500-3500. Manual - part 128

7. Install pinion into the housing (2) and place front

pinion bearing onto the pinion shaft. Draw the pin-
ion shaft into the front bearing with Installer 8981
(1).

8. Install new pinion seal with Installer 8896 (2) and

Handle C-4171 (1).

9. Rotate pinion several times to seat bearings.

10. Apply a light coat of teflon sealant to the pinion

flange splines.

11. Hold pinion and lightly tap the pinion flange (2)

onto the pinion, until a few threads are showing.

12. Install pinion flange washer and new pinion nut.

13. Hold pinion flange (2) with Flange Wrench 8979

(1) and tighten pinion nut until pinion end play is
taken up.

3 - 344

REAR AXLE - 11 1/2 AA

DR/DH

14. Measure pinion rotating torque (1) with an inch

pound torque wrench (2). Tighten pinion nut in
small increments until pinion rotating torque is:

•

New Pinion Bearings: 1.7-2.8 N·m (15-25 in.
lbs.)

•

Original Pinion Bearings: 1.1-2.2 N·m (10-20
in. lbs.)

15. Rotate pinion several times then verify pinion

rotating torque again.

16. Position the ring gear (2) on differential case (4)

and start two new ring gear bolts.

17. Install the rest of the new ring gear bolts and

tighten them alternately to seat the ring gear.

18. Torque ring gear bolts to 237 N·m (175 ft. lbs.).

DR/DH

REAR AXLE - 11 1/2 AA

3 - 345

19. If exciter ring was removed, position differential

assembly on differential Plug 8965 and place
exciter ring (1) on the differential case.

20. Install the exciter ring on the differential case

evenly with a hammer and brass punch (2). Drive
the ring down until it is seated against the ring
gear (2).

21. Install differential in housing and verify gear back-

lash and gear contact pattern.

22. Measure final rotating torque with an inch pound

torque wrench. The final pinion rotating torque
plus differential case bearing preload is:

•

New Bearings: 3.4-5.6 N·m (30-50 in. lbs.)

•

Original Bearings: 2.8-5.1 N·m (25-45 in. lbs.)

23. Install axle shafts.

24. Install the propeller shaft with the reference marks

aligned.

25. Install differential cover with gasket and tighten bolts to 40 N·m (30 ft. lbs.).

26. Fill differential with fluid and tighten fill plug to 32 N·m (24 ft. lbs.).

3 - 346

REAR AXLE - 11 1/2 AA

DR/DH

REAR AXLE - 248RBI

TABLE OF CONTENTS

page

page

REAR AXLE - 248RBI

DIAGNOSIS AND TESTING

REAR AXLE - 248RBI

. . . . . . . . . . . . . . . . . 347

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

. . . . . . . . . . . . . . . . . . . . . . . . 354

. . . . . . . . . . . . . . . . . . . . . . . 355

. . . . . . . . . . . . . . . . . . . . . . 364

. . . . . . . . . . . . . . . . . . . . . . . 366

SHAFT-AXLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

. . . . . . . . . . . . . . . . . . . . . . . . 371

SEAL-AXLE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

. . . . . . . . . . . . . . . . . . . . . . . . 373

BEARING-AXLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

. . . . . . . . . . . . . . . . . . . . . . . . 375

SEAL-PINION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

. . . . . . . . . . . . . . . . . . . . . . . . 377

DIFFERENTIAL-TRAC-LOK

. . . . . . . . . . . . . . . . . . . . . . . . 378

. . . . . . . . . . . . . . . . . . . . . . . . . . 379

DIAGNOSIS AND TESTING

DIFFERENTIAL-TRAC-LOK

. . . . . . . . . . . . . 379

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

. . . . . . . . . . . . . . . . . . . . . . . . 384

. . . . . . . . . . . . . . . . . . . . . . . . . . . 387

. . . . . . . . . . . . . . . . . . . . . . . . 389

BEARING-DIFFERENTIAL CASE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

. . . . . . . . . . . . . . . . . . . . . . . . 392

GEAR-PINION/RING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

. . . . . . . . . . . . . . . . . . . . . . . . 397

REAR AXLE - 248RBI

DIAGNOSIS AND TESTING

REAR AXLE - 248RBI

GEAR NOISE

Axle gear noise can be caused by insufficient lubricant, incorrect backlash, incorrect pinion depth, 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 acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate 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:

•

Check for insufficient lubricant.

•

Incorrect ring gear backlash.

•

Gear 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 vehicle turns. A worn pinion
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 growling sound.

Pinion bearings have a constant-pitch noise. This noise changes with vehicle speed. Pinion bearing noise will be
high pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing noise occurs,
the rear pinion bearing is the source of the noise. If bearing noise is heard during a coast, the front pinion bearing
is the source.

DR/DH

REAR AXLE - 248RBI

3 - 347

Content .. 126 127 128 129 ..