Dodge Ram Truck 1500-2500-3500. Manual — part 104
9. Rotate pinion with an inch pound torque wrench
(2). Rotating torque should be equal to the reading
recorded during removal plus an additional 0.56
N·m (5 in. lbs.).
CAUTION: Never loosen pinion nut to decrease
pinion bearing rotating torque and never exceed
specified preload torque. If rotating torque is
exceeded, a new collapsible spacer must be
installed.
10. If rotating torque is low, use Holder 6719 to hold
the companion flange (1) and tighten pinion nut in
6.8 N·m (5 ft. lbs.) increments until proper rotating
torque is achieved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 N·m (210 ft. lbs.).
11. Install propeller shaft with the installation reference marks aligned.
12. Tighten the companion flange bolts to 108 N·m (80 ft. lbs.).
13. Install brake rotors.
14. Check the differential lubricant level.
COVER-DIFFERENTIAL
REMOVAL
1. With vehicle in neutral, position vehicle on hoist.
2. Remove drain plug.
3. Remove cover bolts.
4. Remove cover and drain lubricant.
INSTALLATION
1. Apply a 6.35mm (1/4 in.) bead of Mopar Silicone
Rubber Sealant (1) or equivalent to the cover (2).
CAUTION: If housing cover is not installed within
3 to 5 minutes, the cover must be cleaned and
new RTV applied. Failure to follow these instruc-
tions will result in a leak.
2. Install cover and identification tag. Tighten cover
bolts in a criss-cross pattern to 41 N·m (30 ft. lbs.).
3. Fill differential to specifications.
4. Install fill plug.
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REAR AXLE - 9 1/4
DR/DH
DIFFERENTIAL
REMOVAL
1. Remove filler plug from the differential cover.
2. Remove differential cover and drain the lubricant.
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 differential case.
6. Mark differential housing and bearing caps (3) for
installation reference.
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 (1) with Wrench C-4164 (3).
10. Hold differential case while removing bearing caps
and adjusters.
NOTE: Tag the differential bearing cups and
threaded adjusters to indicate their location.
11. Remove differential case.
DR/DH
REAR AXLE - 9 1/4
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DISASSEMBLY
1. Rotate one pinion gear (2) with thrust washer (3) to
the differential window (1) and remove gear and
thrust washer.
2. Rotate remaining pinion gear (3) with thrust washer
(2) to the differential window (1) and remove gear
and washer.
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REAR AXLE - 9 1/4
DR/DH
3. Remove differential side gears (1) (2) and thrust
washers.
ASSEMBLY
NOTE: If same gears and thrust washers are being
used, install them into their original locations.
1. Lubricate all differential components with axle lubri-
cant.
2. Install
differential
side
gears
(2)
and
thrust
washers.
DR/DH
REAR AXLE - 9 1/4
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