Dodge Ram Truck 1500-2500-3500. Manual — part 94
4. Remove differential side gears (1) (2) and thrust
washers.
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their orignial loca-
tions.
1. Lubricate all differential components with axle lubri-
cant.
2. Install
differential
side
gears
(2)
and
thrust
washers.
3 - 208
FRONT AXLE - 9 1/4 AA
DR/DH
3. Rotate the one pinion gear (3) with thrust washer
into the differential case. Then rotate the other pin-
ion gear with thrust washer into the differential
case.
4. Align hole in the pinion gears with hole in the dif-
ferential case.
5. Install pinion shaft.
6. Install new pinion shaft lock bolt and tighten to 52
N·m (38 ft. lbs.).
INSTALLATION
1. Clean the housing cavity with a flushing oil, light
engine oil or lint free cloth.
2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the
housing (1).
4. Install bearing caps (2) and bolts. Tighten the bear-
ing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this
time.
5. Slide differential case toward the pinion gear until
the gears make contact/zero backlash. If zero
backlash cannot be obtained, turn the pinion side
adjuster until zero backlash is obtained.
6. Holding the differential case toward the pinion gear,
turn bearing adjusters with Spanner Wrench 8883
until they make contact with the differential bear-
ings/cups.
7. Back off the ring gear side adjuster 4 holes, to
obtain initial ring gear backlash.
8. Install ring gear side adjuster lock and bolt. Do not
tighten adjuster lock bolt at this time.
9. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
10. Rotate the pinion several times to seat the differential bearings.
11. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
12. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
13. Tighten pinion gear side adjuster an additional:
•
New Bearings: 6 Adjuster Holes
•
Original Bearings: 4 Adjuster Holes
DR/DH
FRONT AXLE - 9 1/4 AA
3 - 209
14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
15. Tighten bearing cap bolts (4) to 85 N·m (63 ft.
lbs.).
16. Tighten adjuster lock bolts (3) to 25 N·m (18 ft.
lbs.).
17. Measure ring gear backlash and check gear tooth
contact pattern. Refer to Adjustments for proce-
dure.
18. Install axle shafts and hub bearings.
19. Install
differential
housing
gasket
and
cover.
Tighten cover bolts to 40 N·m (30 ft. lbs.).
20. Fill differential with lubricant.
21. Install fill plug and tighten to 32 N·m (24 ft. lbs.).
BEARING-DIFFERENTIAL CASE
REMOVAL
1. Remove the differential case from the housing.
2. Install Plug 8888 (4) into the end of the case.
3. Remove differential case bearings (3) with Bearing
Splitter 1130 (2) and Bridge 938 (1).
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FRONT AXLE - 9 1/4 AA
DR/DH
INSTALLATION
1. Set differential case (2) on Plug 8888.
2. Install differential case bearings (3) with Installer
8881 (4) and Handle C-4171 (1).
3. Install differential case into housing.
DIFFERENTIAL-ELECTRIC LOCKER
DIAGNOSIS AND TESTING
1. Lift one front wheel of the ground.
2. Turn key to the on position.
3. Place vehicle in drive/first gear and transfer case in LOW LOCK.
4. Activate locker switch.
5. Manually rotate the wheel that is off the ground. The wheel should lock once the dog clutch is aligned.
6. Turn off locker switch.
7. Manually rotate the wheel that is off the ground. The wheel should turn.
DR/DH
FRONT AXLE - 9 1/4 AA
3 - 211
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