Chrysler RAM TRUCK 2500 1994 Service Manual page 148

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REAR SUSPENSION AND AXLE 3 - 41
Fig. 43 Ring Gear Backlash Measurement
(3) Insert a small pry bar between the bearing cap
and right side of differential case. Pry the case as far
as possible to left side (Fig. 43). Zero the dial indica­
tor pointer.
(4) Repeat the measurement several times to check
consistency. Record the travel distance.
The measurement above shows shim thick­
ness necessary to eliminate ring gear backlash.
The shims must be placed at the ring gear
flange side between the case and bearing. Sub­
tract this thickness from case zero end-play
shim thickness. This amount plus 0.38mm (0.015
in.) will be required for differential bearing
preload and backlash. These shim must be
placed on the opposite side.
(5) Remove indicator and pilot stud.
(6) Remove the differential case from housing.
(7) Remove the master bearing tools from the dif­
ferential case hubs.
(8) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear­
ing on the hub with Installer C-4190 and Handle
C-4171.
(9) Position the remaining zero end-play shims on
hub at opposite side of case. Include an additional
0.015-in (0.38-mm) thick shim on this hub. This will
provide the required differential bearing preload
torque.
(10) Install bearing on the hub with Installer
C-4190 and Handle C-4171.
(11) Match each bearing cup with bearing (origi­
nal). Install the cups on the bearings.
(12) Position Spreader W-129B with the tool dowel
pins seated i n the locating holes (Fig. 44). Install the
holddown clamps and tighten the tool turnbuckle fin­
ger-tight.
SPECIAL TOOL
Fig. 44 Differential Housing Separation
(13) Install a pilot stud at the left side of the dif­
ferential housing. Attach Dial Indicator to housing
pilot stud. Load the indicator plunger against the op­
posite side of the housing (Fig. 44) and zero the indi­
cator.
CAUTION: Do not spread over the specified dis­
tance. If the housing is over-separated, it could be
distorted or damaged.
(14) Separate the housing enough to install the
case i n the housing. Separate housing a maxi­
mum distance of 0.38 mm (0.015 in) with the
spreader tool. Measure the distance with the dial
indicator.
(15) Remove the dial indicator.
(16) Install case i n the housing. Ensure the differ­
ential bearings are fully seated. Remove the
spreader.
(17) Observe the assembly reference marks and po­
sition the bearing caps at their original locations
(Fig. 45). Tighten the bearing cap bolts to 95-122 N-m
(70-90 ft. lbs.) torque.
(18) Rotate the assembly several revolutions to
seat bearings. Measure backlash at three equally
spaced locations with a dial indicator (Fig. 46).
The ring gear backlash must be within 0.004 -
0.009 inch (0.10 - 0.23 mm). It cannot vary more
than 0.002 inch (0.05 mm) between the points
checked.
(19) Excessive backlash is corrected by moving the
ring gear teeth closer to the pinion gear teeth. Insuf­
ficient backlash is corrected by moving the ring gear
away from the pinion gear. Backlash correction is ac­
complished by transferring shims from one side to
the other.