Dodge 2001 Ram 1500 Owner's Manual page 162

BR/BE
REAR AXLE - 9 1/4 (Continued)
and differential housing on opposite sides of the hub
(Fig. 15) .
Fig. 15 Side Gear Clearance
1 - FEELER GAUGE
2 - SIDE GEAR
(3) If side gear clearances is no more than 0.005
inch. Determine if the axle shaft is contacting the
pinion 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 shaft, the side
gear clearance is acceptable.
(4) If clearance is more than 0.005 inch (axle shaft
not contacting pinion shaft), record the side gear
clearance. Remove the thrust washer and measure
its thickness with a micrometer. Add the washer
thickness to the recorded side gear clearance. The
sum of gear clearance and washer thickness will
determine required thickness of replacement thrust
washer (Fig. 16). In some cases, the end of the axle
Fig. 16 Side Gear Calculations
shaft will move and contact the pinion 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 mea-
sure the thrust washer thickness. Record the thick-
ness 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 clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
REAR AXLE - 9 1/4 3 - 89