DRIVELINEAXLES Front Axle - 235 AA (9 14) - Ram Pickup PDF

2014 RAM 3500 HD Laramie
2014 DRIVELINE/AXLES Front Axle - 235 AA (9 1/4) - Ram Pickup
2014 DRIVELINE/AXLES
Front Axle - 235 AA (9 1/4) - Ram Pickup
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - NOISE
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Worn wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash 4. Check adjustment of the ring
between the ring gear and pinion. gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion 5. Adjust the pinion bearings pre-
gear bearings. load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact 7. Inspect and replace as
surfaces. necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and
inspect and repair clutch as
necessary.
Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears
differential bearings. and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
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Avoid excessive vehicle weight.

4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid
type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
differential with the correct fluid
type and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean and seal cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage.
Ensure ring gear backlash is
correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
fluid type and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion
adjustment. contact pattern.
3. Unmatched ring gear and 3. Replace gears with a matched
pinion. ring gear and pinion.
4. Worn teeth on ring gear and 4. Replace ring gear and pinion.
Thursday, November 16, 2017 18:55:59 Page 2

pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-
load.
7. Ring gear run-out. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap 8. Inspect differential components
bolts. and replace as necessary. Ensure
that the bearing caps are torqued to
the proper specification.
9. Housing not machined properly. 9. Replace housing.
FLUID CHECK
Filling an axle to the bottom of the fill hole may result in an over fill condition. This can cause fluid foaming
which will result in inadequate lubrication to the axle components. To check axle fluid, park vehicle on a level
surface. Take a piece of wire and make a 90 degree bend two inches from the end of the wire. Insert the wire
into the fill plug hole and use it like a dipstick. Remove the wire and measure from the 90 degree bend to the oil
level. Refer to SPECIFICATIONS for the correct measurement.
GEAR NOISE
Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears
or the carrier housing not having the proper offset and squareness.
Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving
condition. These conditions are acceleration, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the
vehicle to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise
range. If the noise stops or changes greatly check for:
Insufficient lubricant.
Incorrect ring gear backlash.
Gear damage.
Differential side gears and pinions can be checked by turning the vehicle. The side gears are loaded during
turns. They usually do not cause noise during straight-ahead driving when the gears are unloaded. A worn
pinion mate shaft can also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential, pinion bearings and wheel bearings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling sound.
Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise

will be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing
noise occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the
front pinion bearing is the source.
Differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing
noise. The pitch of differential bearing noise is also constant and varies only with vehicle speed.
Axle shaft bearings or Wheel end bearings produce noise and vibration when worn or damaged. The noise
generally changes when the bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and
to the right. This will load the bearings and change the noise level. Where axle bearing damage is slight, the
noise is usually not noticeable at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock is generally caused by:
Worn U-joint(s).
Worn side-gear thrust washers.
Worn pinion shaft bore.
VIBRATION
Vibration at the front/rear of the vehicle is usually caused by:
Damaged drive shaft.

Missing drive shaft balance weight(s).
Worn or out of balance wheels.
Loose wheel lug nuts.
Worn U-joint(s).
Loose/broken springs.
Damaged axle shaft bearing(s).
Loose pinion gear nut.
Excessive pinion yoke run out.
Bent axle shaft(s).
Check for loose or damaged front end components or engine/transmission mounts. These components can
contribute to what appears to be a vibration. Do not overlook engine accessories, brackets and drive belts.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged) can be caused by:
High engine idle speed.

Transmission shift operation.

Loose engine/transmission/transfer case mounts.

Worn U-joints.
Loose spring mounts.
Loose pinion gear nut and yoke.
Excessive ring gear backlash.
Excessive side gear to case clearance.
The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a
hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear and listen for the noise.
A mechanics stethoscope is helpful in isolating the source of a noise.
ADJUSTMENTS
ADJUSTMENTS
PINION DEPTH MEASUREMENT
Fig. 1: Pinion Gear Depth Gauge Tools

Courtesy of CHRYSLER GROUP, LLC
Ring and pinion gears are supplied as matched sets. Compensation for pinion depth variance is achieved with a
select shim located between the rear pinion bearing and pinion gear head.
Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take
measurements with Pinion Gauge Set and Dial Indicator (special tool #C-3339A, Set, Dial Indicator).

1. Assemble Pinion Height Block (special tool #6739, Block, Height) (3), Pinion Block (special tool #8878,
Gauge, Pinion Height) (6) and rear pinion bearing onto Screw (special tool #6741, Screw) (5).
Fig. 2: Identifying Pinion Height Block

2. Insert assembled pinion height block (1), pinion block (2), rear bearing and screw into the housing
through pinion bearing cups.
3. Install front pinion bearing and Cone-Nut (special tool #6740, Cone) onto the screw. Tighten cone-nut
until Torque To Rotate the screw is 1.7 - 2.26 N.m (15 - 20 in. lbs.).
Fig. 3: Gauge Tools In Housing


4. Place Arbor Disc (special tool #8289, Set, Arbor Disc) (4) on Arbor (special tool #D-115-3, Arbor) (3) in
position in the housing side bearing cradles.
5. Install differential bearing caps on arbor discs and snug the bearing cap bolts. Then cross tighten cap bolts
to 85 N.m (63 ft. lbs.).
NOTE: Arbor (3) should rotate freely in the arbor disc (4).
Fig. 4: Identifying Pinion Depth Measurement Tools

6. Assemble Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) into Scooter Block (special tool
#D-115-2A, Block, Scooter) (3) and secure set screw.
7. Position Scooter Block/Dial Indicator flush on the pinion height block. Hold scooter block and zero the
dial indicator (1).
8. Slowly slide the scooter block across the pinion height block over to the arbor. Move scooter block till
dial indicator crests the arbor (2), then record the highest reading.
9. Select a shim equal to the dial indicator reading.

Fig. 5: Pinion Rotating Torque

10. Install select shim between rear pinion bearing and the pinion gear head.
11. Install pinion gear and establish Pinion Torque To Rotate (PTTR) with and inch pound torque wrench (2).
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH

Fig. 6: Adjuster Lock Bolt

Backlash is adjusted by moving the adjusters in and out or both. By moving the adjusters the case/ring gear will
move closer or further away from the pinion. In most cases this adjustment can be used to achieve the correct
gear tooth pattern and set the case bearing preload.
1. Remove adjuster lock bolts (3) and adjuster locks (2).

2. Loosen the differential bearing caps.
3. Slide differential case (1) 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.
4. Holding the differential case toward the pinion gear, turn bearing adjusters with Wrench (special tool
#8883A, Wrench, Differential Adjusting) until they make contact with the differential bearings/cups.
5. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
6. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
7. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
8. Rotate the pinion several times to seat the differential bearings.
9. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup, then tighten it until it
makes contact.
10. Tighten pinion gear side adjuster an additional:
New Bearings: 6 Adjuster Holes
Original Bearings: 4 Adjuster Holes
11. Install pinion gear side adjuster lock and bolt.
12. Tighten bearing cap bolts to 85 N.m (63 ft. lbs.).
13. Tighten adjuster lock bolts to 25 N.m (18 ft. lbs.).

Fig. 7: Measuring Ring Gear Backlash

14. Measure ring gear backlash with a Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) and Dial
Indicator Stud (special tool #L-4438, Dial Indicator Post) at eight points around the drive side of the ring
gear (2). The backlash should be 0.08 - 0.25 mm (0.003 - 0.010 in) with a preferred backlash of 0.13 -
0.18 mm (0.005 - 0.007 in).
NOTE: Backlash measurement should not vary more than 0.05 mm (0.002 in) between
measuring points. If measurement does vary inspect the gears for burrs, the
differential case flange and ring gear mounting.
GEAR TOOTH CONTACT PATTERN
Fig. 8: Identifying Correct Gear Tooth Pattern

1. Wipe clean each tooth of the ring gear.

2. Apply gear marking compound to all of the ring gear teeth.
3. Verify bearing cap bolts are torque to specification.
4. Apply the brakes lightly to create a 14 N.m (10 ft. lbs.) pinion rotating torque.
5. Rotate the pinion/pinion yoke 4 full revolutions in each directions.
6. Read gear tooth contact pattern.
Gear contact pattern is correct. Backlash and pinion depth is correct.

Fig. 9: Incorrect Backlash (1 Of 4)

Ring gear too far away from pinion gear, coast side toe (1) and drive side heel (2). Decrease backlash, by
moving the ring closer to the pinion gear using the adjusters.

Ring gear too close to pinion gear, drive side toe (1) and coast side heel (2). Increase backlash, by moving the
ring away from the pinion gear using the adjusters.

Ring gear too far away from pinion gear, drive side heel (1) and coast side heel (2). Decrease backlash, by
moving the ring closer to the pinion gear using the adjusters.

Ring gear too close to pinion gear, drive side toe (1) and coast side toe (2). Increase backlash, by moving the
ring away from the pinion gear using the adjusters.
Fig. 13: Low Pinion Height

Pinion gear set too low. Increase pinion gear height, by increasing the pinion depth shim thickness.

Fig. 14: High Pinion Height

Pinion gear set too high. Decrease pinion depth, by decreasing the pinion depth shim thickness.
SPECIFICATIONS
SPECIFICATIONS
AXLE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Axle Ratio 3.73, 4.10, 4.56
Ring Gear Diameter 235 mm (9.25 in.)
Ring Gear Backlash 0.13 - 0.18 mm (0.005 - 0.007 in.)
Pinion Torque To Rotate - New Bearing 1.7 - 2.8 N.m (15 - 25 in. lbs.)
Pinion Torque To Rotate - Original Bearing 1.1 - 2.2 N.m (10 - 20 in. lbs.)
Total Torque To Rotate - New Bearing 3.4 - 5.6 N.m (30 - 50 in. lbs.)
Total Torque To Rotate - Original Bearing 2.8 - 5.1 N.m (25 - 45 in. lbs.)
Fluid Fill Level 2.2L +/- 0.2L
TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Fill Hole Plug 32 24 -
Differential Cover Bolts 40 30 -
Bearing Cap Bolts 85 63 -
Ring Gear Bolts 140 103 -
Axle Nut 356 263 -
Pinion Shaft Lock Bolt 52 38 -
Adjuster Lock Bolt 25 18 -
4WD Actuator Bolt 22 16 -
REMOVAL

REMOVAL
1. With vehicle in neutral, position vehicle on hoist.

2. Remove brake calipers and rotors.
3. Disconnect ABS wheel speed sensors.
Fig. 15: Brake Line Bracket Bolt

4. Remove the brake line bracket bolt (1) from the control arm brackets.

Fig. 16: Removing Brake Line Bolt

5. Remove the brake line bolt (1) from the coil spring lower bracket.
6. Disconnect axle vent hose.
7. Remove front propeller shaft.

Fig. 17: Identifying 4WD Shift Actuator & Bolts

8. Disconnect the 4WD actuator (2) connector.

9. Remove stabilizer bar links at the axle brackets.
10. Remove track bar bolt from the axle. Refer to TRACK BAR, FRONT, REMOVAL .
Fig. 18: Left Tie Rod End And Steering Knuckle

11. Disconnect the left tie rod end (1) from the steering knuckle.

Fig. 19: Right Tie Rod, Drag Link And Axle Bracket
12. Disconnect the right tie rod (1) from the steering knuckle.
13. Disconnect the drag link (2) from the right steering knuckle.
14. Disconnect the steering damper from the axle bracket (3).
NOTE: Secure steering components that are not removed.
15. Position lift under the axle assembly and secure axle to lift.
16. Mark suspension alignment cams for installation reference.

Fig. 20: Lower/Upper Control Arm Bolts And Lower Shock Absorber Bolt
17. Remove lower shock absorbers bolts (1) from axle brackets.
18. Remove the upper and lower bolts (2 and 3) from the left and right control arms.
19. Lower the axle. The coil springs will drop with the axle.
20. Remove coil springs from the axle bracket.
INSTALLATION
INSTALLATION
CAUTION: Suspension components with rubber bushings should be tightened with

the weight of the vehicle on the suspension. Failure to follow these
instructions will result in damage.
1. Support the axle on a suitable lifting device.

2. Secure axle to lifting device.
3. Position the axle under the vehicle.
4. Install springs retainer clip and bolts.
5. Raise axle and align it with the spring pads.
6. Position the left and right control arms in the axle brackets. Install bolts, nuts and align the suspension
alignment cams to the reference marks made upon axle removal. Do not tighten at this time.

Fig. 21: Lower/Upper Control Arm Bolts And Lower Shock Absorber Bolts
7. Install the lower shock absorber bolts (1) and torque to 136 N.m (100 ft. lbs.).
8. Install the track bar. Refer to TRACK BAR, FRONT, INSTALLATION .
9. Install drag link to the right steering knuckle. Refer to DRAG LINK, STEERING, LINK AND COIL,
INSTALLATION .
10. Install the tie rod ends to the steering knuckles. Refer to END, TIE ROD, LINK AND COIL,
INSTALLATION .
11. Connect the sway bar links. Refer to LINK, STABILIZER BAR, INSTALLATION .
12. Install ABS wheel speed sensors.

Fig. 22: Brake Line Bracket And Bolt

13. Install the brake line bracket and bolt (1) to the coil spring brackets.
Fig. 23: Brake Line Bracket And Bolt


14. Install the brake line bracket and bolt (1) to the control arm brackets.
15. Install rotors and brake calipers.
16. Connect the axle vent hose.
17. Install front propeller shaft.

18. Connect the 4WD actuator (2) electrical connector.

Fig. 25: Lower/Upper Control Arm Bolts And Lower Shock Absorber Bolts
19. With vehicle on the ground, tighten control arms bolts (2 and 3) on left and right sides, upper and lower.
Refer to FRONT, LINK AND COIL, SPECIFICATIONS .
20. Tighten track bar bolt at the axle bracket. Refer to FRONT, LINK AND COIL, SPECIFICATIONS .
21. Check front wheel alignment.
SPECIAL TOOLS
SPECIAL TOOLS
1130 - Splitter, Bearing/Gear

(Originally Shipped In Kit Number(s)
6745, 6947, 6949, 9202, 9202A-CAN,
9202CC, 9299.)

6310 - Remover, Bearing/Seal

8207, 8418, XJ594, XJ595.)
6310-2 - Disc
8207, 8418, XJ594, XJ595.)

6310-7 - Nut
8207, 8418, XJ594, XJ595.)
6310-9 - Head
8207, 8418, XJ594, XJ595.)

6739 - Block, Height

6730, 9516A-CAN, 9540, 9541.)

6740 - Cone
6730, 6731, 9516A-CAN, 9540, 9541.)
6741 - Screw
6730, 6731, 9516A-CAN, 9540, 9541.)
8289 - Set, Arbor Disc

8887, 8887CC.)

8411 - Installer, Seal

8655.)
8476 - Installer, Seal

8708.)

8498 - Receiver, Axle Shaft Seal

8887, 8887CC, 9972.)

8878 - Gauge, Pinion Height

8887, 8887CC.)
8879 - Adapters, Puller

8887, 8887CC.)

8881 - Installer, Bearing

8887, 8887CC.)
8882 - Installer, Pinion Seal

8887, 8887CC.)

8883A - Wrench, Differential Adjusting

8887.)
8885-1 - Installer Seal Plate

8887, 8887CC.)

8885-2 - Assembly, Screw

8887, 8887CC.)

8886 - Installer, Bearing Cup

8887, 8887CC.)
8888 - Plug, Differential Bearing

8887, 8887CC.)

8976 - Pinion Driver

8887, 8887CC, 9925, 9926.)
8979 - Wrench, Pinion Flange

8999.)
8982 - Installer, Pinion

8887, 8887CC.)

8992 - Remover, Pinion Flange

8999, 8999CC, 9299, 9299CC, 9299CC,
9300A-CAN.)

938 - Bridge
6745, 6947, 6949, 9202, 9202A-CAN,
9202CC, 9299.)
9611 - Plug, Differential End

9690.)

9612 - Installer, Bearing

9690.)

9613 - Adapters, Puller

9690, 9720-SUP.)
C-293-PA - Puller, Press

8418, 8837, C-293-M.)
C-3095-A - Installer, Bearing

C-3339A - Set, Dial Indicator

9202.)
C-3894-A - Puller, Tie Rod

9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)

C-4171 - Driver Handle, Universal

9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)
D-115-2A - Block, Scooter

9329-SUP, 9515-SUP, 9516-SUP, 9517-
SUP, 9518, 9519, 9540-SUP, 9541-SUP,
9694, 9926.)

D-115-3 - Arbor
8667, 9516A-CAN.)
D-146 - Installer, Bearing Cup

8667.)

L-4438 - Dial Indicator Post
ACTUATOR, AXLE LOCKER

REMOVAL
REMOVAL
1. Place a drain pan under axle actuator.

2. Disconnect the electrical connector.


3. Remove the four mounting bolts (1) from the 4WD actuator (2).
Fig. 27: Removing 4WD Shift Actuator


4. Remove the 4WD actuator (1) from the axle.
INSTALLATION
INSTALLATION
1. Check O-ring gasket on actuator and replace if necessary.
Fig. 28: Installing 4WD Shift Actuator

2. Install 4WD actuator (1), aligning the locating pin on the actuator and the fork with the intermediate shaft
collar.


3. Install the actuator bolts (1) and tighten to 22 N.m (16 ft. lbs.).
4. Connect the 4WD actuator electrical connector.
5. Check axle fluid level, replace any lost fluid. Refer to CAPACITIES AND RECOMMENDED
FLUIDS, SPECIFICATIONS .
6. Verify operation of the 4WD system.
BEARING, DIFFERENTIAL SIDE

REMOVAL
REMOVAL
1. Remove the differential from the housing.

2. Install (special tool #9611, Plug, Differential End) (3) into the end of the differential assembly.

Fig. 30: Removing Differential Side Bearing

3. Install (special tool #C-293-PA, Puller, Press) (2) onto the differential side bearing.
4. Install (special tool #8879, Adapters, Puller) (4) between the bearing (1) and C-293-PA (2).
5. Remove the differential side bearing by tightening C-293-PA.
NOTE: The bridge of C-293-PA could be placed in a proper vise to assist in the
removal of the differential bearing.
INSTALLATION
INSTALLATION

Fig. 31: Pressing Bearing Onto The Differential

NOTE: New differential side bearing must be installed. Reinstalling used bearing could
affect the operation of the axle.
1. Place the differential (3) in a suitable press with (special tool #8888, Plug, Differential Bearing) (4)
installed in the differential at the bottom.
2. Place a NEW bearing (2) on the differential.
3. Using (special tool #8881, Installer, Bearing) (1) press the bearing onto the differential.
BEARING, DIFFERENTIAL SIDE, ELECTRIC LOCKER

REMOVAL
REMOVAL

Fig. 32: Removing Differential Case Bearings

1. Remove the differential case from the housing.

2. Bend anti-rotation tabs outwards.
3. Install Plug (special tool #9611, Plug, Differential End) (1) into the end of the case.
4. Remove differential case bearings (2) with Puller (special tool #C-293-PA, Puller, Press) (3) and
Adapters (special tool #9613, Adapters, Puller) (4).
INSTALLATION
INSTALLATION

Fig. 33: Installing Differential Case Bearings

1. Install differential case bearings (1) with Handle (special tool #C-4171, Driver Handle, Universal) (2) and
Installer (special tool #9612, Installer, Bearing) (3).
2. Bend anti-rotation tabs back to original location.
CASE ASSEMBLY, DIFFERENTIAL

REMOVAL
REMOVAL
Fig. 34: Differential Housing Cover, Bolts & Plug

1. Remove differential housing cover (2) and drain lubricant from the housing.
2. Remove hub bearings and axle shafts.
NOTE: The right axle seal and intermediate shaft must be removed for the
removal of the differential case assembly.
NOTE: The right axle seal must be removed before the intermediate shaft can be
removed through the axle tube.
3. Disconnect the 4WD actuator electrical connector.


4. Remove four bolts (1) from 4WD shift actuator.


5. Remove the 4WD shift actuator (1).

6. Remove the right axle shaft seal. Refer to SEAL, AXLE DRIVE SHAFT, REMOVAL.
Fig. 37: Intermediate Shaft

7. Remove the intermediate shaft through the right axle tube.
NOTE: Hold the intermediate shaft ball bearing in place while removing the
intermediate shaft through the axle tube.

Fig. 38: Ball Bearing

8. Remove the ball bearing (1) though the 4WD actuator access hole.
Fig. 39: Adjusters And Locks



10. Mark bearing caps (4) left and right for installation reference.
11. Remove bearing cap bolts and remove bearing caps.
Fig. 40: Bearing Cups & Adjusters

12. Loosen differential bearing adjusters (2, 4) with a hammer and punch.
13. Remove differential case from the housing.
14. Remove bearing cups (1, 3) and tag them left and right for installation reference.
DISASSEMBLY
DISASSEMBLY

Fig. 41: Identifying Pinion Shaft, Pinion Gears & Punch

1. Remove pinion shaft lock bolt.

2. Remove pinion shaft (1) from pinion gears (3) with a punch (2).
Fig. 42: Identifying Pinion Gears, Differential Window & Thrust Washer
3. Rotate differential pinion gears (2) to differential window (1) and remove pinion gears and thrust washers
(3).
Fig. 43: Identifying Differential Side Gears


4. Remove differential side gears (1) (2) and thrust washers.
ASSEMBLY
ASSEMBLY
Fig. 44: Identifying Differential Side Gears

NOTE: If same gears and thrust washers are being used, install them into original
locations.
1. Lubricate all differential components with axle lubricant.

2. Install differential side gears (2) and thrust washers.

Fig. 45: Rotating Pinion Gear With Thrust Washer Into Differential Case
3. Rotate one pinion gear (3) with thrust washer into the differential case. Then rotate the other pinion gear
with thrust washer into the differential case.
4. Align hole in the pinion gears with hole in the differential case.
5. Install pinion shaft.
6. Install new pinion shaft lock bolt and tighten to 52 N.m (38 ft. lbs.).
INSTALLATION
INSTALLATION

Fig. 46: Case Bearing Cap

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 (1).
4. Install bearing caps (2) and bolts. Tighten the bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this time.
Fig. 47: Adjuster Wrench


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 (2) toward the pinion gear, turn bearing adjusters with Wrench (special tool
#8883A, Wrench, Differential Adjusting) (1) until they make contact with the differential bearings/cups.
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.
14. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.

15. Tighten bearing cap bolts (4) to 85 N.m (63 ft. lbs.).
16. Tighten adjuster 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
procedure.


18. Install the intermediate shaft ball bearing in the axle tube.


19. Install the intermediate shaft (1). Slide the shaft all the way into the ball bearing.
20. Replace the right side axle seal. Refer to SEAL, AXLE DRIVE SHAFT, INSTALLATION.
Fig. 51: 4WD Shift Collar & Intermediate Shaft

21. Install the 4WD shift collar onto the intermediate shaft.


22. Install the 4WD shift actuator and torque the bolts to 22 N.m (16 ft. lbs.).
23. Connect the 4WD actuator connector.
24. Install axle shafts and hub bearings.

Fig. 53: Differential Housing Cover, Bolts & Plug

25. Install differential housing gasket and cover. Tighten cover bolts to 40 N.m (30 ft. lbs.).
26. Fill differential with lubricant to specifications.
27. Install fill plug and tighten to 32 N.m (24 ft. lbs.).
CASE ASSEMBLY, DIFFERENTIAL, ELECTRIC LOCKER

DESCRIPTION
DESCRIPTION
Fig. 54: Identifying Tie Strap And Target Sensor

The electric locker differential has an 12 volt electromagnetic coil on the ring gear side of the differential. When
the coil is energized a dog clutch is engaged in the differential case which locks both axles. A 5 volt magnetic
target sensor (1) mounted on the bearing cap is used to indicate the system has been activated.
NOTE: System will time out within 2 minutes, when the key is in the on position and the
engine is not running.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - DIFFERENTIAL-ELECTRIC LOCKER

1. Position vehicle on host with wheels of the ground.

2. Turn key to the on position.
NOTE: System will time out within 2 minutes, when the key is in the on position
and the engine is not running.
3. Place vehicle in drive/first gear and transfer case in LOW LOCK.

4. Activate locker switch and lock rear axle.
5. Activate locker switch for front axle.
6. Hold one wheel and rotate the other wheel which should lock once the dog clutch is aligned.
7. Turn off locker switch.
8. Hold one wheel and rotate the other wheel which should turn.
NOTE: Only the locker actuator with sensor is serviced. Internal differential
components are serviced as a differential case assembly.
REMOVAL
REMOVAL

1. Remove differential housing cover and drain lubricant from the housing.

3. Cut sensor wire tie strap (4) from adjuster lock.

4. Remove sensor target magnet (1) from bearing cap.

Fig. 57: Electric Locker Connector & Retainer


6. Remove electric locker connector (1) retainer (2) bolt from differential housing.
Fig. 58: Electric Locker Connector Retainer & O-Ring

7. Remove retainer (1) and connector (2) from differential housing.

8. Remove retainer (1) from connector (2) and remove O-ring (3) from connector.
9. Mark bearing caps left and right for installation reference.
10. Loosen bearing cap bolts and loosen adjusters with a hammer and punch.
11. Remove bearing cap bolts and bearing caps.
12. Slid electric locker connector through differential housing.
13. Remove differential case and bearing cups from the housing.
14. Tag bearing cups left and right for installation reference.
DISASSEMBLY
DISASSEMBLY

Fig. 59: Removing Differential Case Bearings

NOTE: Internal differential components are serviced with the case.
1. Bend anti-rotation tabs outward.

2. Install Plug (special tool #9611, Plug, Differential End) (1) into coil side of the case.
3. Remove differential case bearing (2) with Puller (special tool #C-293-PA, Puller, Press) (3) and Adapters
(special tool #9613, Adapters, Puller) (4).
Fig. 60: Removing Coil & Mounting Bolts


4. Remove coil (1) mounting bolts (2).

5. Remove coil (1) with harness.
ASSEMBLY
ASSEMBLY
Fig. 61: Positioning Locker Coil On Differential Case

NOTE: Internal differential components are serviced with the case.
1. Position locker coil on differential case (1) mounting location (2).

Fig. 62: Installing Coil & Mounting Bolts

2. Clean coil bolts and apply Mopar® Lock AND Seal adhesive to the threads.
3. Install coil (1) and bolts (2).
Fig. 63: Installing Differential Case Bearings

4. Install differential case bearing (1) with Handle (special tool #C-4171, Driver Handle, Universal) (2) and
Installer (special tool #9612, Installer, Bearing) (3).
INSTALLATION

INSTALLATION
Fig. 64: Electric Locker Connector & Retainer

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. Slide electric locker connector through differential housing.
5. Install O-ring on electric locker connector.
6. Install electric locker connector (1) with retainer (2) in differential housing.
7. Install connector retainer and bolt.

Fig. 65: Case Bearing Cap

NOTE: Do not torque bearing cap and bolts at this time.
8. Install bearing caps (2) and tighten bearing cap bolts finger-tight.
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 Wrench (special tool
#8883A, Wrench, Differential Adjusting) until they make contact with the differential bearings/cups.
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.


18. Tighten bearing cap bolts (4) to 85 N.m (63 ft. lbs.).
19. Install adjuster locks (2) and tighten bolts (3) to 25 N.m (18 ft. lbs.).


21. Install sensor target magnet (1) on bearing cap.
22. Energize locker and rotate axle shaft. Verify dog clutch is engaged by rotating one axle while holding the
other. If engaged axle will not rotate.
23. De-energize locker and rotate left axle 15 to 40 degrees so dog clutch gears will not engage.
NOTE: System will time out within 2 minutes when the key is in the on position
and the engine is not running.
NOTE: If the axle is locking and the indicator light continues to flash, the sensor
gap is too small. If the axle is disengaged and the indicator light stays on,
the sensor gap is to large. Gap adjustment must be within spec.
24. Energize locker and set sensor air gap (2) to 5.05 mm ± 0.25 mm (0.20 in. ± 0.01 in.).
25. Tighten sensor target magnet bolt (3) to 7 N.m (62 in. lbs.).
NOTE: The next step will verify the sensor air gap was adjusted with the dog
clutch gears ear to ear.
26. Hold right axle and rotate left axle until dog clutch engages with an audible click nose.
27. Install sensor wire tie strap (4) in the original location or at white dot on wiring harness to the top leg of
adjuster lock and de-energize coil.
28. Measure ring gear backlash and check gear tooth contact pattern. Refer to ADJUSTMENTS for
procedure.
29. Install differential housing gasket and cover. Tighten cover bolts to 40 N.m (30 ft. lbs.).
30. Fill differential with lubricant.
31. Install fill plug and tighten to 32 N.m (24 ft. lbs.).
GEAR, RING AND PINION

REMOVAL
REMOVAL

Fig. 68: Ring Gear

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 installation alignment.

2. Disconnect propeller shaft from pinion flange and remove propeller shaft.
3. Remove axle shafts.
4. Remove differential from housing. Refer to CASE ASSEMBLY, DIFFERENTIAL, REMOVAL or
CASE ASSEMBLY, DIFFERENTIAL, ELECTRIC LOCKER, REMOVAL.
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).
Fig. 69: Flange Wrench

8. Hold pinion flange (1) with Flange Wrench (special tool #8979, Wrench, Pinion Flange) (2) and remove
pinion flange nut and washer.
Fig. 70: Identifying Pinion Flange And Puller

9. Remove pinion flange (1) from pinion with Pinion Flange Puller (special tool #8992, Remover, Pinion
Flange) (2).
Fig. 71: Identifying Pinion Gear And Driver

10. Remove pinion gear (1) from housing with Pinion Driver (special tool #8976, Pinion Driver) (2) and a
hammer.
NOTE: Thread drive on shaft until it bottoms out.

11. Remove pinion seal with a slide hammer or pry bar.

12. Remove and discard front pinion bearing.
13. Remove collapsible spacer from the pinion shaft.
Fig. 72: Rear Pinion Bearing

14. Remove rear pinion bearing with Puller (special tool #C-293-PA, Puller, Press) (1) and Adapters (special
tool #8879, Adapters, Puller) (4).
15. Remove pinion depth shim from the pinion gear shaft and record thickness of the shims.
16. Remove front pinion bearing cup from the housing with a punch and hammer and discard cup.
17. Remove rear pinion bearing cup from the housing with a punch and hammer, if bearing is replaced.
INSTALLATION
INSTALLATION

Fig. 73: Front Pinion Bearing Cup

1. Install rear pinion bearing cup with Installer (special tool #D-146, Installer, Bearing Cup) (1) and Handle
(special tool #C-4171, Driver Handle, Universal) (2).
Fig. 74: Installing Front Pinion Bearing Cup With Installer

2. Install front pinion bearing cup with Installer (special tool #8886, Installer, Bearing Cup) (1) and Handle
(special tool #C-4171, Driver Handle, Universal) (2), if bearing is replaced.

Fig. 75: Installing Pinion Depth Shim

3. Install pinion depth shim (1) on the pinion gear (2) shaft.
Fig. 76: Installing Rear Pinion Bearing


4. Install rear pinion bearing (4) with Installer (special tool #C-3095-A, Installer, Bearing) (2) and a press
(1).
Fig. 77: Installing Collapsible Spacer On Pinion Gear

5. Install new collapsible spacer (1) on pinion gear (2).

6. Lubricate pinion and bearings (3).
Fig. 78: Installing Pinion Into Housing

7. Install pinion in housing (2) and place front pinion bearing on pinion shaft. Draw pinion shaft into the
front bearing with Installer (special tool #8982, Installer, Pinion) (1).

Fig. 79: Installing Pinion Seal

8. Install new pinion seal with Installer (special tool #8882, Installer, Pinion Seal) (2) and Handle (special
tool #C-4171, Driver Handle, Universal) (1).
9. Apply a light coat of teflon sealant to the pinion flange splines.
10. Hold pinion and lightly tap the pinion flange onto the pinion shaft, until a few threads are showing.
11. Install pinion flange washer and new pinion nut.
12. Hold pinion flange with Flange Wrench (special tool #8979, Wrench, Pinion Flange) and tighten pinion
nut until end play is eliminated.

13. Rotate pinion several times to seat pinion bearings.

14. Measure Pinion Torque To Rotate (1) with an inch pound torque wrench (2). Tighten pinion nut in 6.8
N.m (5 ft. lbs.) increments until pinion torque to rotate is reached.
Pinion Torque To Rotate is:
New Pinion Bearings: 1.7 - 2.8 N.m (15 - 25 in. lbs.)

Original Pinion Bearings: 1.1 - 2.2 N.m (10 - 20 in. lbs.)
15. Rotate pinion several times then verify pinion torque to rotate again.
16. Position ring gear on differential case and start two new ring gear bolts.
17. Install remaining new ring gear bolts and tighten them alternately to seat the ring gear. Torque ring gear
bolts to 140 N.m (103 ft. lbs.).
18. Install differential in housing. Refer to CASE ASSEMBLY, DIFFERENTIAL, INSTALLATION or
CASE ASSEMBLY, DIFFERENTIAL, ELECTRIC LOCKER, INSTALLATION.
19. Measure Total Torque to Rotate (TTTR) with an inch pound torque wrench.
Total Torque to Rotate is:
New Bearings: 3.4 - 5.6 N.m (30 - 50 in. lbs.)

Original Bearings: 2.8 - 5.1 N.m (25 - 45 in. lbs.)
NOTE: If TTTR is to high, back off adjusters evenly on both sides slightly
and check TTTR again. If TTTR is to low, tighten adjusters evenly on
both sides slightly and check TTTR again.
20. Verify ring gear backlash and gear contact pattern.
SEAL, AXLE DRIVE SHAFT

REMOVAL
REMOVAL
LEFT
NOTE: If replacing the left axle seal the right axle seal must be replaced as well.


Fig. 82: Removing The 4WD Shift Collar


3. Remove the 4WD shift collar (2).

4. Remove the right axle shaft seal. Refer to SEAL, AXLE DRIVE SHAFT, REMOVAL.

5. Slide the intermediate shaft (1) out the right axle tube.
NOTE: Hold the ball bearing (2) in place while removing the intermediate shaft.
6. Remove differential from differential housing.

7. Remove differential bearing adjusters.

Fig. 84: Removing Axle Seals

8. Remove axle seal (2) located behind adjusters with Receiver (special tool #8498, Receiver, Axle Shaft
Seal) and Extractor (special tool #6310, Remover, Bearing/Seal).
Fig. 85: Installing Receiver Into The Adjuster Bore

9. Install Receiver (special tool #8498, Receiver, Axle Shaft Seal) (1) into the adjuster bore.
10. Install Extractor Rod (special tool #6310, Remover, Bearing/Seal) with Extractor Foot (special tool
#6310-9, Head) (2) through the receiver and axle seal.

Fig. 86: Identifying Seal Extractor Rod & Nut

11. Install Extractor Plate (special tool #6310-2, Disc) and Nut (special tool #6310-7, Nut) (2) on the
extractor rod (1).
12. Tighten nut (2) on extractor rod (1) to pull seal into the receiver.
RIGHT
NOTE: The differential does not need to be removed to service the right axle seal.
1. Remove right side hub bearing and axle shaft.


Fig. 88: Removing The 4WD Shift Collar


3. Remove the 4WD shift collar (2).

4. Remove the right side axle shaft seal using (special tool #8476, Installer, Seal), (special tool #C-4171,
Driver Handle, Universal) and (special tool #C-4171-2, Extension, Drive Handle)
5. Drive the axle seal inward to remove it.
INSTALLATION
INSTALLATION
LEFT
Fig. 89: 4WD Shift Collar & Intermediate Shaft

NOTE: The differential and the right axle seal must be removed to replace the left axle
seal.
1. Install a new seal onto (special tool #8885, Installer, Axle Seal) (3) puck and place it in position.
2. Install (special tool #5058A, Compressor, Spring) threaded rod (1) through the axle tube.
3. Install (special tool #8411, Installer, Seal) (2) behind the seal and 8885 installer.
4. From the outer axle tube, thread 5058-A until the left axle seal is seated.
RIGHT


1. Install intermediate shaft ball bearing (1), if removed.


2. Install intermediate shaft (1), if removed.
Fig. 92: Placing The Axle Seal

3. Place the axle seal onto (special tool #8885-1, Installer Seal Plate) (2).

Fig. 93: Identifying Special Tool Component

4. Using (special tool #6310-7, Nut) (4), (special tool #6310-2, Disc) (3) and (special tool #5058A,
Compressor, Spring) (7) connect the two threaded rods together with the 6310-7 nut.
5. Thread a generic 1/2 x 13 nut (6) to (special tool #6310-7, Nut) so the threaded rods do not un-thread.
(using as a jam nut).
6. Slide the threaded rod though the axle tube, place (special tool #8885-1, Installer Seal Plate) (2) and seal
through the threaded rod.
7. Thread (special tool #8411, Installer, Seal) (1) behind 8885-1 using it as support.
Fig. 94: Turning Bolt On Threaded Rod

8. Turn bolt (2) on threaded rod (1) until right axle seal is seated.
NOTE: Use these tools for axle seal installation or
equivalent.

Fig. 95: Installing The 4WD Shift Collar

9. Install the 4WD shift collar (2).


10. Install the 4WD shift actuator (1) and torque bolts to 22 N.m (16 ft. lbs.).
11. Connect the 4WD shift actuator connector.
12. Install the axle shaft and hub bearing.
13. Verify correct fluid level.
SEAL, DRIVE PINION

REMOVAL
REMOVAL

1. Mark propeller shaft and pinion flange (1) for installation reference.
2. Remove propeller shaft.
4. Rotate pinion gear three or four times.
5. Record pinion torque to rotate (1) with an inch pound torque wrench (2) for installation reference.


6. Hold pinion flange (1) with Flange Wrench (special tool #8979, Wrench, Pinion Flange) (2) and remove
pinion flange nut and washer.
Fig. 99: Removing Pinion Flange

7. Mark a line across the pinion shaft and flange for installation reference.
8. Remove pinion flange (1) with Pinion Flange Puller (special tool #8992, Remover, Pinion Flange) (2).

Fig. 100: Removing Pinion Seal With Puller

9. Remove pinion seal (3) with a seal puller (2).
INSTALLATION
INSTALLATION
Fig. 101: Installing Pinion Seal With Installer

1. Install new pinion seal with Installer (special tool #8882, Installer, Pinion Seal) (2) and Handle (special
tool #C-4171, Driver Handle, Universal) (1).
2. Apply a light coat of teflon thread sealant, to pinion flange splines.


3. Install flange on the pinion shaft with the reference marks aligned.
4. Lightly tap pinion flange onto the pinion, until a few threads are showing.
5. Install flange washer and new pinion nut.
6. Hold flange (1) with Flange Wrench (special tool #8979, Wrench, Pinion Flange) (2) and tighten pinion
nut until pinion end play is taken up.


7. Rotate pinion flange (1) several times to seat bearings.

8. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should
be equal to recorded reading plus an additional 0.40-0.57 N.m (3-5 in. lbs.).
9. If torque to rotating is low, tighten the pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion torque to
rotate is achieved.
10. Rotate pinion several times then verify pinion torque to rotate again.
12. Install propeller shaft with reference marks aligned.
SHAFT, AXLE
REMOVAL
REMOVAL
1. With the vehicle in neutral, position vehicle on hoist.

2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped.
Fig. 104: Removing Axle Shaft Hub Nut

3. Remove axle shaft hub nut (1).

Fig. 105: Hub Bearing Bolts

4. Remove four hub bearing bolts (2) from the back of the steering knuckle.
5. Remove hub bearing from the steering knuckle.
Fig. 106: Identifying Axle Shaft And Steering Knuckle

6. Remove axle shaft (2) from steering knuckle (1) and axle housing.
INSTALLATION

INSTALLATION
Fig. 107: Installing Axle Shaft Through Steering Knuckle

1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore.
2. Install axle shaft (2) through the steering knuckle (3) and into the differential side gears.
Fig. 108: Hub Bearing Bolts

3. Install hub bearing in the knuckle.

4. Install hub bearing bolts (2) and tighten to 202 N.m (149 ft. lbs.).
5. Install ABS wheel speed sensor, brake rotor and caliper.
Fig. 109: Axle Nut

6. Install axle nut (1). Tighten axle nut to 179 N.m (132 ft. lbs.).
7. Rotate axle several 5 to 10 times to seat the wheel bearing.
8. Tighten axle nut (1) to final torque of 356 N.m (263 ft. lbs.).
U-JOINT, SINGLE CARDAN

REMOVAL
REMOVAL

Fig. 110: Removing Bearing Cap Snap Rings

NOTE: Saturate bearing caps with penetrating oil prior to removal.
1. Remove axle shaft.

2. Remove bearing cap snap rings (1) from stub shaft yoke (2) bearing caps.
Fig. 111: Pressing Bearing Cup Into Receiver/Socket


3. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into
receiver/socket (2).
Fig. 112: Removing Bearing Cap From Stub Shaft Yoke

4. Remove bearing cap (1) from stub shaft yoke (2).


5. Position receiver/socket (2) under stub shaft yoke (3) remaining bearing cup and driver/socket (1) on U-
joint cross in press. Press bearing cup into receiver/socket (2)
Fig. 114: Removing Bearing Cap From Stub Shaft Yoke

6. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross.
Fig. 115: Snap Rings & Shaft Yoke


7. Remove snap rings (1) from shaft yoke (2) bearing caps.

8. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into
receiver/socket (2).
Fig. 117: Removing Bearing Cap From Shaft Yoke


9. Remove bearing cap (1) from shaft yoke (2).

10. Position receiver/socket (2) under shaft yoke (3) remaining bearing cup and driver/socket (1) on U-joint
cross in press. Press bearing cup into receiver/socket (2)
Fig. 119: Removing Bearing Cap From Shaft Yoke


11. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke.
INSTALLATION
INSTALLATION
Fig. 120: Positioning Cross In Shaft Yoke

CAUTION: Keep cross and bearing cap straight during installation. Failure to follow
these instruction will result in damage.
1. Pack bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
2. Position cross (1) in the shaft yoke (2).

Fig. 121: Positioning Receiver/Socket On Shaft Yoke And Driver/Socket On Bearing Cap In Press
3. Tap bearing cap into the yoke bores far enough to position cross.
4. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press.
Fig. 122: Pressing Bearing Cap Into Shaft Yoke

5. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2).

Fig. 123: Positioning Receiver/Socket & Driver/Socket

Fig. 124: Pressing Bearing Cap Into Shaft Yoke & Installing Snap Ring
7. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2).

Fig. 125: Installing Stub Shaft Yoke On U-Joint Cross

8. Install stub shaft yoke (1) on U-joint cross (2).
Fig. 126: Positioning Receiver/Socket & Driver/Socket

9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross.

Fig. 127: Pressing Bearing Cap Into Stub Shaft Yoke & Installing Snap Ring
11. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap
ring (2).
Fig. 128: Positioning Receiver/Socket On Stub Shaft Yoke And Driver/Socket On Bearing Cap In
Press

12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press.
Fig. 129: Pressing Bearing Cap Into Stub Shaft Yoke And Installing Snap Ring
13. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap
ring (2).
14. Install axle shaft.

DRIVELINEAXLES Front Axle - 235 AA (9 14) - Ram Pickup PDF

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DRIVELINEAXLES Front Axle - 235 AA (9 14) - Ram Pickup PDF

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2014 RAM 3500 HD Laramie

2014 DRIVELINE/AXLES Front Axle - 235 AA (9 1/4) - Ram Pickup

Front Axle - 235 AA (9 1/4) - Ram Pickup

DIAGNOSIS AND TESTING

Thursday, November 16, 2017 18:56:02

Avoid excessive vehicle weight.

Thursday, November 16, 2017 18:55:59 Page 2

Thursday, November 16, 2017 18:55:59 Page 3

LOW SPEED KNOCK

Low speed knock is generally caused by:

Vibration at the front/rear of the vehicle is usually caused by:

Damaged drive shaft.

High engine idle speed.

Thursday, November 16, 2017 18:55:59 Page 4

Loose engine/transmission/transfer case mounts.

PINION DEPTH MEASUREMENT

Fig. 1: Pinion Gear Depth Gauge Tools

Thursday, November 16, 2017 18:55:59 Page 5

Fig. 2: Identifying Pinion Height Block

Fig. 3: Gauge Tools In Housing

Thursday, November 16, 2017 18:55:59 Page 6

Fig. 4: Identifying Pinion Depth Measurement Tools

Thursday, November 16, 2017 18:55:59 Page 7

Fig. 5: Pinion Rotating Torque

DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH

Thursday, November 16, 2017 18:55:59 Page 8

Fig. 6: Adjuster Lock Bolt

1. Remove adjuster lock bolts (3) and adjuster locks (2).

Thursday, November 16, 2017 18:55:59 Page 9

Fig. 7: Measuring Ring Gear Backlash

GEAR TOOTH CONTACT PATTERN

Fig. 8: Identifying Correct Gear Tooth Pattern

1. Wipe clean each tooth of the ring gear.

Gear contact pattern is correct. Backlash and pinion depth is correct.

Thursday, November 16, 2017 18:55:59 Page 10

Fig. 9: Incorrect Backlash (1 Of 4)

Fig. 10: Incorrect Backlash (2 Of 4)

Fig. 11: Incorrect Backlash (3 Of 4)

Thursday, November 16, 2017 18:55:59 Page 11

Courtesy of CHRYSLER GROUP, LLC

Fig. 12: Incorrect Backlash (4 Of 4)

Fig. 13: Low Pinion Height

Thursday, November 16, 2017 18:55:59 Page 12

Fig. 14: High Pinion Height

Thursday, November 16, 2017 18:55:59 Page 13

1. With vehicle in neutral, position vehicle on hoist.

Fig. 15: Brake Line Bracket Bolt

Thursday, November 16, 2017 18:55:59 Page 14

Fig. 16: Removing Brake Line Bolt

Thursday, November 16, 2017 18:55:59 Page 15

Fig. 17: Identifying 4WD Shift Actuator & Bolts

8. Disconnect the 4WD actuator (2) connector.

Fig. 18: Left Tie Rod End And Steering Knuckle

Thursday, November 16, 2017 18:55:59 Page 16

NOTE: Secure steering components that are not removed.

Thursday, November 16, 2017 18:55:59 Page 17

CAUTION: Suspension components with rubber bushings should be tightened with

1. Support the axle on a suitable lifting device.

Thursday, November 16, 2017 18:55:59 Page 18

Thursday, November 16, 2017 18:55:59 Page 19

Fig. 22: Brake Line Bracket And Bolt

Fig. 23: Brake Line Bracket And Bolt

Thursday, November 16, 2017 18:55:59 Page 20