Front Axle - 275FBI: Removal & Installation RAM Pickup 2500

INSTALLATION

1. Secure axle to lifting device.
2. Align axle under the vehicle.
3. Install springs, retainer clip and bolts.
4. Raise axle and align it with the spring pads.
5. Install lower control arms (1) in the axle brackets. Install bolts (2) and nuts and hand tighten nuts.
6. Install upper control arms (1) in the axle brackets. Install bolts and nuts (2) and hand tighten nuts.
7. Install track bar in axle bracket and install bolt and nut hand tighten.
8. Install shock absorbers (1) and install nuts (3) and bolts (4) hand tighten.
9. Install stabilizer bar link (1) in axle bracket and tighten nut (2) to 150 N.m (111 ft. lbs.).
10. Install track bar and tighten bolt to 54 N.m (40 ft. lbs.)
11. Install drag link and tie rod to the steering knuckles.
12. Install steering damper in axle bracket and tighten to 75 N.m (55 ft. lbs.).
13. Install rotors, brake calipers, and ABS wheel speed sensors.
14. Install brake hose retainers (1) and bolts (2).
15. Install axle vent hose.
16. Install propeller shaft (1) with all reference marks aligned.
17. Install transfer case companion flange (2) bolts and tighten to 88 N.m (65 ft. lbs.).
18. Install new axle companion flange (3) bolts and tighten to 28 N.m (21 ft. lbs.). NOTE: Companion flange bolts incorporate a Loctite R patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite R 242 to the threads.
19. Lower vehicle on the ground and tighten the following components at the axle: Upper control arm nuts - 250 N.m (184 ft. lbs.) Lower control arm nuts - 375 N.m (400 ft. lbs.) Shock absorber nuts - 136 N.m (100 ft. lbs.) Track bar bolt - 370 N.m (273 ft. lbs.)
20. Check front wheel alignment.

REMOVAL

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.

1. Clean sealing surface on cover and housing.
2. Apply a 4 mm (0.15 in.) bead of Mopar AXLE RTV (1) or equivalent to the housing. CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak.
3. Install cover (1) and tighten bolts (2) in a criss-cross pattern to 46 N.m (34 ft. lbs.).
4. Fill differential to specifications.
5. Install cover (1) fill plug (2) and tighten to 60 N.m (44 ft. lbs.).

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.

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1. Remove differential case from the axle housing.
2. Remove ring gear bolts (1) from ring gear (2).
3. Separate ring gear from differential case.
4. Bend pinion flange (1) nut (2) collar out pinion shaft keyway with a hammer and punch.
5. Hold pinion flange (1) with Holder (special tool #C-3281, Holder, Flange) (2) and remove 50 mm pinion nut.
6. Remove pinion flange (1) with Puller (special tool #8992, Remover, Pinion Flange) (2).
7. Drive pinion out of the housing with a dead blow hammer.
8. Remove pinion bearing preload shim (1) from pinion gear (2).
9. Remove pinion spacer (1) from pinion gear (2).
10. Position Splitter (special tool #1130, Splitter, Bearing/Gear) under the rear pinion bearing (2).
11. Press pinion rear bearing (1) of the pinion shaft (2) with a press.
12. Remove pinion seal with a seal puller.
13. Remove front pinion bearing (1) from axle housing (2).
14. Remove front pinion bearing cup (1) with a hammer and brass drift (2).
15. Remove rear pinion bearing cup (1) with a hammer and brass drift (2).
16. Remove pinion depth shim (1) from rear pinion bearing cup bore.

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1. Install front pinion bearing cup with Installer (special tool #10093, Installer, Bearing Cup) (1) and handle (special tool #C-4171, Driver Handle, Universal) (2).
2. Install pinion depth shim (1) in rear pinion bearing cup bore.
3. Install rear pinion bearing cup with Installer (special tool #10093, Installer, Bearing Cup) (1) and handle (special tool #C-4171, Driver Handle, Universal) (2). WARNING: Use tongs or welding gloves when handling heated components. Failure to follow these instructions will result in personal injury. CAUTION: Pinion bearings (1) are installed using a Bearing Heater (2). Use only a bearing heater/hot plate and follow manufacture's instructions. Heat components to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.
4. Heat rear pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on pinion (2) with tongs or welding gloves.
5. Rear pinion bearing (1) can also be installed with Installer (special tool #8148, Cup) (2) and a press.
6. Install pinion spacer (1) on pinion gear (2).
7. Install pinion bearing preload shim (1) on pinion gear (2).
8. Install pinion gear (1) into differential housing.
9. Heat front pinion bearing to 100 - 149 Celsius (212° Min. - 300° Max Fahrenheit) and install bearing (1) on pinion (2) with tongs or welding gloves.
10. Install pinion seal with Installer (special tool #10069, Installer, Seal) (1).
11. Install pinion flange on pinion shaft.
12. Hold pinion flange (1) with Holder (special tool #C-3281, Holder, Flange) (2) and tighten pinion flange nut to 500 N.m (369 ft. lbs.).
13. Bend pinion flange (1) nut (2) collar into pinion keyway with a hammer and punch.
14. Align ring gear (1) to differential case with two new ring gear bolts (2).
15. Install remaining new ring gear bolts and tighten to 175 N.m (139 ft. lbs.).
16. Install differential into housing.
17. Check Total Torque To Rotate. TTTR is: Pinion Torque To Rotate plus 1.5 N.m ± 0.5 N.m (13 in. lbs. ± 4.4 in. lbs.). NOTE: If TTTR is too high, decrease shim thickness equally from both sides of the differential and check TTTR again. If TTTR is too low, increase shim thickness equally to both sides of the differential and check TTTR again.
18. Verify ring gear backlash and gear contact pattern.

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1. With the vehicle in neutral, position vehicle on hoist.
2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor.
3. Bend axle shaft hub nut (1) collar out of the axle keyway.
4. Remove axle shaft hub nut (1).
5. Remove four hub bearing bolts (1) from the back of the steering knuckle.
6. Remove hub bearing from the steering knuckle.
7. Remove axle shaft (1) with hub bearing shim (2) from axle.
8. Remove axle seal (1) from axle yoke with seal puller (2).

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1. Install axle shaft seal into axle yoke with Installer (special tool #10011, Installer, Seal) (1) Handle (special tool #C-4171, Driver Handle, Universal) (2).
2. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore.
3. Install axle shaft (1) with hub bearing shim (2) into the axle.
4. Install hub bearing in the knuckle.
5. Install hub bearing bolts (1) and tighten to 200 N.m (147 ft. lbs.).
6. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper.
7. Install axle hub nut (3) and tighten nut to 330 N.m (243 ft. lbs.).
8. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch.

1. With the vehicle in neutral, position vehicle on hoist.
2. Remove propeller shaft.
3. Bend pinion flange (1) nut (2) collar lock out of the pinion shaft keyway.
4. Hold pinion flange (1) with Holder (special tool #C-3281, Holder, Flange) (2) and remove pinion flange nut.
5. Mark a line across the pinion shaft and flange for installation reference.
6. Remove pinion flange (1) with Pinion Flange Puller (special tool #8992, Remover, Pinion Flange) (2).
7. Remove pinion seal with a seal puller.

1. Install new pinion seal with Installer (special tool #10069, Installer, Seal) (1).
2. Apply a light coat of Teflon thread sealant, to pinion flange splines.
3. Position flange on pinion shaft with reference marks aligned.
4. Install pinion flange (1) new pinion nut.
5. Hold flange with Holder (special tool #C-3281, Holder, Flange) (2) and tighten pinion nut to 500 N.m (369 ft. lbs.).
6. Bend pinion flange (1) nut (2) collar into pinion keyway with a hammer and punch.
7. Install propeller shaft with reference marks aligned.

1. With the vehicle in neutral, position vehicle on hoist.
2. Remove brake caliper, caliper adapter, hub extension, rotor and ABS sensor.
3. Bend axle shaft hub nut (1) collar out of the axle keyway.
4. Remove axle shaft hub nut (1).
5. Remove four hub bearing bolts (1) from the back of the steering knuckle.
6. Remove hub bearing from the steering knuckle.
7. Remove axle shaft (1) with hub bearing shim (2) from axle.

1. Clean axle shaft and apply a thin film of grease to the shaft splines and hub bore.
2. Install axle shaft (1) with hub bearing shim (2) into the axle.
3. Install hub bearing in the knuckle.
4. Install hub bearing bolts (1) and tighten to 200 N.m (147 ft. lbs.).
5. Install ABS sensor, brake rotor (1), hub extension (2), caliper adapter and caliper.
6. Install axle hub nut (3) and tighten nut to 330 N.m (243 ft. lbs.).
7. Bend axle shaft hub nut (3) collar into axle keyway with a hammer and punch.

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1. Remove bearing cap snap rings (1) from the axle yoke (2) and stub shaft yoke (3). NOTE: Saturate bearing caps with penetrating oil prior to removal.
2. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2).
3. Remove bearing cap (1) from stub shaft yoke (2).
4. 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)
5. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross.
6. Position receiver/socket (2) and driver/socket (1) on shaft yoke (3) in press. Press bearing cup into receiver/socket (2).
7. Remove bearing cap (1) from shaft yoke (2).
8. 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)
9. Remove bearing cap (1) from shaft yoke (2). Then remove U-joint cross from shaft yoke.

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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).
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.
5. Press bearing cap into shaft yoke until bearing cap snap ring groove is visible and install snap ring.
6. Position receiver/socket (1) on shaft yoke (2) and driver/socket on bearing cap in press.
7. Press bearing cap into shaft yoke until bearing cap snap ring groove is visible and install snap ring.
8. Install stub shaft yoke (1) on U-joint cross (2).
9. Tap fist bearing cap into the stub shaft yoke bore far enough to position cross.
10. Position receiver/socket (1) on shaft yoke (2) and driver/socket on bearing cap in press.
11. Press bearing cap into stub shaft yoke until bearing cap snap ring groove is visible and install snap ring.
12. Position receiver/socket (1) on stub shaft yoke and driver/socket (2) on bearing cap in press.
13. Press bearing cap into stub shaft yoke until bearing cap snap ring groove is visible and install snap ring.