Dodge Ram Truck 1500-2500-3500. Manual — part 114

2. Rotate one pinion gear (2) with thrust washer (3) to

the differential window (1) and remove the gear.

3. Rotate other pinion gear (3) with thrust washer (2)

to the differential window (1) and remove the gear.

4. Remove differential side gears (1) (2) and thrust

washers.

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ASSEMBLY

NOTE: If the same gears and thrust washers are
being used, install them into their original loca-
tions.

1. Lubricate all differential components with axle lubri-

cant.

2. Install

differential

side

gears

(2)

and

thrust

washers.

3. Install first pinion gear (3) into the differential win-

dow (1) and side gears (2). Rotate the pinion gear
to the back of the case.

4. Install other pinion gear and thrust washer. Rotate

the gears to align hole in the pinion gears with hole
in the differential case.

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REAR AXLE - 10 1/2 AA

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5. Slide pinion shaft (4) into the case and through the

pinion gears (3). Tap the shaft to seat the pinion
shaft snap-ring (1) into the case.

INSTALLATION

1. Clean the housing (1) cavity with a flushing oil, light

engine oil or lint free cloth.

CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.

2. Lubricate differential case bearing.

3. Install differential case with bearings cups into the

housing.

NOTE: A light coat of grease on the cups will hold
them in place during installation.

4. Install bearing caps (2) and bolts. Tighten the bear-

ing cap bolts finger-tight.

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REAR AXLE - 10 1/2 AA

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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
(1) until they make contact with the differential
bearings/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 differ-

ential 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

14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.

15. Tighten bearing cap bolts to 165 N·m (122 ft.

lbs.).

16. Tighten adjuster (2) 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.

19. Install

differential

housing

gasket

and

cover.

Tighten cover bolts to 40 N·m (30 ft. lbs.).

20. Fill axle with lubricant, refer to Lubrication & Main-

tenance for capacity and lubricant type.

21. Install fill plug and tighten to 32 N·m (24 ft. lbs.).

DR/DH

REAR AXLE - 10 1/2 AA

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