Dodge Ram Truck 1500-2500-3500. Manual — part 117

INSTALLATION

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

engine oil or lint free cloth.

2. Lubricate differential case bearing.

3. Install differential case with bearings cups into the

housing.

4. Slid electric locker connector through differential

housing.

5. Install o-ring (2) on electric locker connector.

6. Install electric locker connector retainer (1) and

install connector with retainer in differential hous-
ing.

7. Install connector retainer bolt.

8. Install bearing caps (2), anti rotation bracket and

bolts. Tighten bearing cap bolts finger-tight.

NOTE: Do not torque bearing cap and bolts at this
time.

9. 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.

10. Holding the differential case toward the pinion

gear, turn bearing adjusters with Spanner Wrench
8883 until they make contact with the differential
bearings/cups.

11. Back off the ring gear side adjuster 4 holes, to

obtain initial ring gear backlash.

12. Install ring gear side adjuster lock and bolt. Do

not tighten adjuster lock bolt at this time.

13. Tighten pinion gear side adjuster firmly against

the differential case bearing cup.

14. Rotate the pinion several times to seat the differ-

ential bearings.

15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.

16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.

17. Tighten pinion gear side adjuster an additional:

•

New Bearings: 6 Adjuster Holes

•

Original Bearings: 4 Adjuster Holes

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

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DR/DH

19. Tighten bearing cap bolts (4) to 165 N·m (122 ft.

lbs.).

20. Tighten adjuster (2) lock bolts (3) to 25 N·m (18 ft.

lbs.).

21. Measure ring gear backlash and check gear tooth

contact pattern. Refer to Adjustments for proce-
dure.

22. Install axle shafts.

23. Install

differential

housing

gasket

and

cover.

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

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

tenance for capacity and lubricant type.

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

BEARINGS-EL DIFFERENTIAL CASE

REMOVAL

1. Remove the differential case from the housing.

2. Install Plug 8888 (1) into the end of the case.

3. Remove differential case bearings (2) with Puller

C-293-PA (3) and Adapters 9614 (4 ).

DR/DH

REAR AXLE - 10 1/2 AA

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INSTALLATION

1. Install differential bearings (1) with Handle C-4171

(2) and Installer 8956 (3).

GEAR-PINION/RING

REMOVAL

NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.

1. Mark pinion flange and propeller shaft for installa-

tion alignment.

2. Disconnect propeller shaft from pinion flange and

remove propeller shaft.

3. Remove differential from axle housing.

4. Place differential on Plug 8888 and drive exciter

ring (4) off the differential case (1) with a hammer
and punch (3).

NOTE: Do not remove the exciter ring if it is not
being replaced.

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5. Place differential case in a vise with soft metal jaw

protectors

6. Remove bolts holding ring gear to differential case.

7. Drive ring gear (2) from differential case (1) with a

soft hammer (3).

8. Hold pinion flange (1) with Flange Wrench 8979 (2)

and remove pinion flnage nut and washer.

9. Remove pinion flange (1) from the pinion with

Flange Puller 8992 (2).

DR/DH

REAR AXLE - 10 1/2 AA

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