Dodge Ram Truck 1500-2500-3500. Manual — part 101

Ring gear too far away from pinion gear, coast side
toe (1) and drive side heel (2). Decrease backlash, by
moving the ring closer to the pinion gear using the
adjusters.

Ring gear too close to pinion gear, drive side toe (1)
and coast side heel (2). Increase backlash, by moving
the ring away from the pinion gear using the adjusters.

Ring gear too far away from pinion gear, drive side
heel (1) and coast side heel (2). Decrease backlash,
by moving the ring closer to the pinion gear using the
adjusters.

Ring gear too close to pinion gear, drive side toe (1)
and coast side toe (2). Increase backlash, by moving
the ring away from the pinion gear using the adjusters.

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REAR AXLE - 9 1/4

DR/DH

Pinion gear set too low. Increase pinion gear height,
by increasing the pinion depth shim thickness.

Pinion gear set too high. Decrease pinion depth, by
decreasing the pinion depth shim thickness.

SIDE GEAR CLEARANCE

When measuring side gear (2) clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.

1. Install the axle shafts and C-locks and pinion mate

shaft.

2. Measure

each

side

gear

clearance.

Insert

a

matched pair of feeler gauge (1) blades between
the gear and differential housing on opposite sides
of the hub.

3. If side gear clearances is no more than 0.005 inch.

Determine if the axle shaft is contacting the pinion
mate shaft. Do not remove the feeler gauges,
inspect the axle shaft with the feeler gauge
inserted behind the side gear. If the end of the
axle shaft is not contacting the pinion mate shaft,
the side gear clearance is acceptable.

DR/DH

REAR AXLE - 9 1/4

3 - 237

4. If clearance is more than 0.005 inch (axle shaft not

contacting mate shaft), record the side gear clear-
ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick-
ness to the recorded side gear clearance. The sum
of gear clearance and washer thickness will deter-
mine required thickness of replacement thrust
washer.

In some cases, the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted.
The C-lock is preventing the side gear from sliding on the axle shaft.

5. If there is no side gear clearance, remove the C-lock from the axle shaft. Use a micrometer to measure the

thrust washer thickness. Record the thickness and re-install the thrust washer. Assemble the differential case
without the C-lock installed and re-measure the side gear clearance.

6. Compare both clearance measurements. If the difference is less than 0.012 inch (0.305 mm), add clearance

recorded when the C-lock was installed to thrust washer thickness measured. The sum will determine the
required thickness of the replacement thrust washer.

7. If clearance is 0.012 inch (0.305 mm) or greater, both side gears must be replaced (matched set) and the clear-

ance measurements repeated.

8. If clearance (above) continues to be 0.012 inch (0.305 mm) or greater, the case must be replaced.

SPECIFICATIONS

AXLE SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Axle Ratio

3.21, 3.55, 3.92

Differential Case Flange Runout

0.076 mm (0.003 in.)

Differential Case Clearance

0.12 mm (0.005 in.)

Ring Gear Diameter

235 mm (9.25 in.)

Ring Gear Backlash

0.12-0.20 mm (0.005-0.008 in.)

Ring Gear Runout

0.12 mm (0.005 in.)

Pinion Bearing Preload - New Bearings

1.7-4 N·m (15-35 in. lbs.)

Pinion Bearing Preload - Original Bearings

1-2 N·m (10-20 in. lbs.)

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Differential Cover Bolts

41

30

-

Bearing Cap Bolts

136

100

-

Ring Gear Bolts

157

115

-

Pinion Nut Minimum

285

210

-

Adjuster Lock Screw

10

7.5

90

Backing Plate Bolts

65

48

-

Pinion Mate Shaft Lock

Screw

11

8

-

Axle U-Bolt Nuts

149

110

-

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REAR AXLE - 9 1/4

DR/DH

SPECIAL TOOLS

PULLER C-293-PA

PLUG C-293-3

ADAPTERS C-293-37

ADAPTERS C-293-47

INSTALLER C-3095-A

DIAL INDICATOR SET C-3339

INSTALLER C-3718

INSTALLER C-4076-B

WRENCH C-4164

DR/DH

REAR AXLE - 9 1/4

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