Chrysler RAM TRUCK 2500 1994 Service Manual page 124

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REAR SUSPENSION AND AXLE 3 - 17
( 4 ) Inspect the differential side and pinion gears.
Replace any gear that is worn, cracked or chipped.
(5) Inspect the differential case. Replace the case i f
cracked or damaged.
Polish each axle shaft with No. 600 crocus
cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft
seal contact surface. When polishing, the crocus
cloth should be moved around the circumfer­
ence of the shaft (not in-line with the shaft).
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them i f necessary.
(7) Test each threaded adjuster to determine i f i t
rotates freely. I f an adjuster binds, repair the dam­
aged threads or replace the adjuster.
EXCITER RING REPLACEMENT
The ring gear must be removed before the RWAL/
ABS brake exciter ring can be replaced.
(1) Remove exciter ring with a hammer and drift.
(2) Heat the replacement exciter ring with a heat
lamp or by immersing i n a hot fluid. The tempera­
ture should not exceed 149°C (300°F). Do not use a
torch to heat the ring.
(3) After heating, quickly position the exciter ring
on the differential case adjacent to the flange.
DIFFERENTIAL CASE ASSEMBLY
When replacing a pinion or differential bear­
ings always replace bearing and cup as a
matched set.
(1) Lubricate all the differential case components
with gear lubricant.
(2) Place thrust washers on differential side gears.
Position the gears i n the differential case counter-
bores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear­
ance Measurement And Adjustment.
(3) Position thrust washers on differential pinion
gears. Mesh the pinion gears with the side gears.
Ensure that the pinion gears are exactly 180 de­
grees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align components with the mate
shaft bores i n the case.
(5) I f the ring gear was removed, clean all contact
surfaces. Use a fine file to remove any sharp areas
from chamfered inside diameter.Heat ring gear with
a heat lamp or immerse in a hot fluid. The tempera­
ture should not exceed 149°C (300°F). Do not use a
torch to heat the ring.
(6) Position heated gear on case. Use two equally
spaced Pilot Studs C-3288-B to align the gear with
the flange holes (Fig. 18).
(7) Install replacement ring gear bolts (with left
hand threads). Alternately and evenly tighten each
bolt to 102 N-m (75 ft. lbs.) torque.
PILOT
Fig. 16 Case-To-Ring Gear Alignment
CAUTION:
W h e n
installing a differential bearing,
never apply force to the bearing cage because bear­
ing damage will result.
(8) Install a differential bearing on each hub with
Installer C-4213 and Handle C-4171.
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Pinion measurement are taken with C-758-D6 Tool
Set (Fig. 19) with pinion bearing cups installed.
SPECIAL TOOL
Fig. 19 9 1/4 Axle Pinion Adjustment Tools
(1) Install front (outer) bearing cup with Tool Set
C-4306 and Handle C-4171.
(2) Install rear (inner) bearing cup with Tool Set
C-4306 and Handle C-4171.
• Position Spacer (SP-6017) over Shaft (SP-526)
• Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
® Install Sleeve (SP-1730)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533)