Front Axle - 275FBI: Component Locations RAM Pickup 2500

SPECIAL TOOLS

10011 - Installer, Seal (Originally Shipped In Kit Number(s) 10045.) 10068 - Adapters, Spreader (Originally Shipped In Kit Number(s) 10045.) 10069 - Installer, Seal (Originally Shipped In Kit Number(s) 10045.) 10091 - Block, Gauge (Originally Shipped In Kit Number(s) 10045.) 10092 - Plug, Differential End (Originally Shipped In Kit Number(s) 10045.) 10093 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 10045.) 10094 - Set, Arbor Disc (Originally Shipped In Kit Number(s) 10045, 9566-SUP2.) 10120 - Bearings, Dummy (Originally Shipped In Kit Number(s) 10045.) 10121 - Cone (Originally Shipped In Kit Number(s) 10045.) 1130 - Splitter, Bearing/Gear (Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9202, 9202A-CAN, 9202CC, 9299.) 6739 - Block, Height (Originally Shipped In Kit Number(s) 6730, 9516A-CAN, 9540, 9541.) 6741 - Screw (Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.) 8148 - Cup (Originally Shipped In Kit Number(s) 8104, 9975.) 8151 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8104.) 8992 - Remover, Pinion Flange (Originally Shipped In Kit Number(s) 8999, 8999CC, 9299, 9299CC, 9299CC, 9300A-CAN.) 938 - Bridge (Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9202, 9202A-CAN, 9202CC, 9299.) C-3281 - Holder, Flange (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) C-3339A - Set, Dial Indicator (Originally Shipped In Kit Number(s) 9202.) C-3894-A - Puller, Tie Rod (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) D-115-2A - Block, Scooter (Originally Shipped In Kit Number(s) 9329-SUP, 9515-SUP, 9516-SUP, 9517-SUP, 9518, 9519, 9540-SUP, 9541-SUP, 9694, 9926.) D-115-3 - Arbor (Originally Shipped In Kit Number(s) 8667, 9516A-CAN.) W-129-B - Spreader, Differential (Originally Shipped In Kit Number(s) 9975.)

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1. Install Plug (special tool #10092, Plug, Differential End) (1) into differential case this way to remove the large bearing (2).
2. Install Splitter (special tool #1130, Splitter, Bearing/Gear) (1) under larger differential bearing (2).
3. Install Bridge (special tool #938, Bridge) (1) on Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) (2) and remove larger differential case bearing.
4. Turn Plug (special tool #10092, Plug, Differential End) (1) over, in other side of the differential case (2) to remove the small differential case bearing.
5. Install Splitter (special tool #1130, Splitter, Bearing/Gear) (1) under small differential bearing (2).
6. Install Bridge (special tool #938, Bridge) on Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) (1) and remove small differential case bearing.

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1. Heat ring gear side differential bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Install bearing (1) on differential (2) with tongs or welding gloves. NOTE: Ring gear side differential bearing can also be install with Installer (special tool #8151, Installer, Bearing Cup) (1) and a press.
2. Heat pinion gear side differential bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Install bearing (1) on differential (2) with tongs or welding gloves.

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1. With vehicle in neutral, position vehicle on hoist.
2. Remove differential cover (1) fill plug (2).
3. Remove differential cover (1) bolts (2).
4. Remove cover and drain lubricant.
5. Remove axle shafts.
6. Loosen differential (1) bearing cap bolts (2).
7. Install Adapters (special tool #10068, Adapters, Spreader) (1) onto the housing (2).
8. Loosen bearing cap bolts.
9. Install Spreader (special tool #W-129-B, Spreader, Differential) (1) onto the adapters and tighten the turnbuckle finger-tight.
10. Mount attach Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (2) to housing and load indicator plunger against the opposite side of the housing. Zero the indicator.
11. Spread the housing, while measuring the distance with the dial indicator (2). CAUTION: Never spread housing over 0.38 mm (0.015 in.). Failure to follow these instruction will damage the housing.
12. Remove dial indicator.
13. Remove bearing caps, differential with bearing cups and preload shims.
14. Remove the spreader.

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Note. Tag all components with location.

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1. Remove ring gear bolts (1) from ring gear (2).
2. Separate ring gear from differential case.
3. Remove thrust washer (1) from side gear (2).
4. Remove side gear (1) from differential case (2).
5. Remove first pinion mate shaft (1) from differential case (2).
6. Remove second pinion mate shaft (1) from differential case (2).
7. Remove first set of pinion gears (1) with thrust washer from differential case (2).
8. Remove third pinion mate shaft (1) from differential case (2).
9. Remove second set of pinion gears (1) with thrust washer from differential case (2).
10. Remove remaining side gear (1) from differential case (2).
11. Remove side gear thrust washer (1) from differential case (2).