Dodge Ram Truck 1500-2500-3500. Manual — part 132

7. With a dead-blow hammer (1), seat the differential

dummy bearings to the pinion side of the housing
(2).

8. With a dead-blow hammer (2), seat the differential

dummy bearings to the ring gear side of the hous-
ing (1).

9. Thread Pilot Stud C-3288-B (3) into rear cover bolt

hole below ring gear.

10. Attach the Dial Indicator C-3339 (4) to pilot stud.

Position the dial indicator plunger on a flat surface
between the ring gear bolt heads.

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11. Push and hold differential case (1) to pinion gear

side of the housing and zero dial indicator (4).

12. Push and hold differential case (2) to ring gear

side of the housing (3) and record the dial indica-
tor (1) reading.

13. Add 0.38 mm (0.015 in.) to the zero end play

total. This total represents the thickness of shims
needed to preload the new bearings when the dif-
ferential is installed.

14. Rotate dial indicator out of the way on the pilot

stud.

15. Remove differential case and dummy bearings

from the housing.

16. Install the pinion gear in the housing. Install the

pinion yoke and establish the correct pinion rotat-
ing torque.

17. Install differential case (5) and dummy bearings

D-343 in the housing (without shims), install bear-
ing caps and tighten bolts snug.

18. Seat ring gear side dummy bearing.

19. Position the dial indicator plunger on a flat surface

between the ring gear bolt heads.

20. Push and hold differential case (2) toward pinion

gear and zero the dial indicator (1).

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21. Push and hold differential case (2) to ring gear

side of the housing and record dial indicator (1)
reading.

22. This is the shim thickness needed on the ring

gear side of the differential case for proper back-
lash.

23. Subtract the backlash shim thickness from the

total preload shim thickness. The remainder is the
shim thickness required on the pinion side of the
housing.

24. Rotate dial indicator out of the way on pilot stud.

25. Remove differential case and dummy bearings

from the housing.

26. Install the selected side bearing shims onto the

differential case hubs.

27. Install side bearings on differential case hubs with Install C-4190 and Handle C-4171.

28. Install bearing cups on differential.

29. Install Spreader W-129-B and some items from Adapter Set 6987 on the housing and spread open enough to

receive differential case.

CAUTION: Never spread housing over 0.50 mm (0.020 in.). Failure to follow these instruction will damage
the housing.

30. Install differential case into the housing.

31. Remove spreader from the housing.

GEAR BACKLASH

1. Rotate the differential case several times to seat

the side bearings.

2. Position the indicator plunger (1) against a ring

gear tooth.

3. Push and hold ring gear upward while not allowing

the pinion gear to rotate.

4. Zero dial indicator face to pointer.

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5. Push and hold ring gear downward while not allow-

ing the pinion gear to rotate. Dial indicator reading
should be between 0.12 mm (0.005 in.) and 0.20
mm (0.008 in.). If backlash is not within specifica-
tions transfer the necessary amount of shim thick-
ness from one side of the housing to the other.

6. Verify differential case and ring gear runout by

measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should
not vary more than 0.05 mm (0.002 in.). If readings
vary more than specified, the ring gear or the dif-
ferential case is defective.

After the proper backlash is achieved, perform Gear
Contact Pattern Analysis procedure.

GEAR CONTACT PATTERN

The ring gear and pinion teeth contact patterns will
show if the pinion depth is correct in the axle housing.
It will also show if the ring gear backlash has been
adjusted correctly. The backlash can be adjusted
within specifications to achieve desired tooth contact
patterns.

The TOP LAND (1) of the gear tooth is the top surface
of the tooth. The PROFILE (2) of the gear tooth is the
depth of the tooth. The TOE (3) of the gear is the por-
tion of the tooth surface at the end towards the center.
The HEEL (4) of the gear is the portion of the tooth at
the outer-end. The ROOT (5) of the gear tooth is the
lowest portion of the tooth.

NOTE: If the PROFILE across the gear tooth is the
same it is a 3 Axis cut gear. If the PROFILE across
the gear tooth is tapered it is a 2 Axis cut gear.

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