Dodge Ram Truck 1500-2500-3500. Manual — part 138
15. Remove case (2) from housing (1) and tag bear-
ing cups (3) and shims location.
16. Remove spreader.
DISASSEMBLY
1. Clamp Holding Fixture 9346 (1) in vise (2) and set
differential case (3) on fixture.
2. Remove pinion gear mate shaft screw.
3. Remove pinion gear mate shaft.
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4. Lubricate and install disc (3), that is not threaded
from Trac-Lok
T
Tool Kit 6960 into the lower side
gear (1).
5. Install threaded disc (6) from Trac-Lok
T
Tool Kit
6960 into top side gear. Thread forcing screw (5)
from Trac-Lok
T
Tool Kit 6960 through top disc until
it comes in contact with lower disc (4).
6. Position a small screw driver (3) in slot of top disc
(2) to prevent disc from turning.
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REAR AXLE - 248RBI
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7. Tighten forcing screw (2) with torque wrench (1) to
122 N·m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs.
8. With a feeler gauge (2) remove thrust washers (1)
from behind the pinion gears.
9. Insert turning bar (2) from tool kit into pinion mate
shaft hole in the case.
10. Loosen forcing screw in small increments until the
clutch pack tension is relieved and differential
case can be turned using turning bar.
11. Rotate differential case until the pinion gears (1)
can be removed.
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12. Remove pinion gears from differential case.
13. Remove forcing screw and discs.
14. Remove top side gear (3), clutch pack (3) and
retainer (2).
NOTE:
Keep
plates
in
correct
order
during
removal.
15. Remove differential case from fixture. Remove
lower side gear, clutch pack retainer and clutch
pack.
ASSEMBLY
Clean all components in cleaning solvent and dry
components with compressed air. Inspect clutch pack
plates (1) for wear, scoring or damage. Replace both
clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
Inspect differential case and pinion shaft. Replace if
worn or damaged.
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs
for a minimum of 20 minutes.
1. Lubricate each component with gear lubricant
before assembly.
2. Assemble clutch discs (1) into packs and secure
disc packs with retaining clips (4).
3. Position differential case on the Holding Fixture
9346.
DR/DH
REAR AXLE - 248RBI
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