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Front Axle - 9 1/4 Aa: Component Locations RAM Pickup 2500

Differentials & Drive Axles 31 illustrations ~1251 words

SPECIAL TOOLS

1130 - Splitter, Bearing/Gear (Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9202, 9202A-CAN, 9202CC, 9299.) 6310 - Remover, Bearing/Seal (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 6310-2 - Disc (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 6310-7 - Nut (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 6310-9 - Head (Originally Shipped In Kit Number(s) 8207, 8418, XJ594, XJ595.) 6739 - Block, Height (Originally Shipped In Kit Number(s) 6730, 9516A-CAN, 9540, 9541.) 6740 - Cone (Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.) 6741 - Screw (Originally Shipped In Kit Number(s) 6730, 6731, 9516A-CAN, 9540, 9541.) 8289 - Set, Arbor Disc (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8498 - Receiver, Axle Shaft Seal (Originally Shipped In Kit Number(s) 8887, 8887CC, 9972.) 8878 - Gauge, Pinion Height (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8879 - Adapters, Puller (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8881 - Installer, Bearing (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8882 - Installer, Pinion Seal (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8883A - Wrench, Differential Adjusting (Originally Shipped In Kit Number(s) 8887.) 8885-1 - Installer Seal Plate (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8885-2 - Assembly, Screw (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8886 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8888 - Plug, Differential Bearing (Originally Shipped In Kit Number(s) 8887, 8887CC.) 8976 - Pinion Driver (Originally Shipped In Kit Number(s) 8887, 8887CC, 9925, 9926.) 8979 - Wrench, Pinion Flange (Originally Shipped In Kit Number(s) 8999.) 8982 - Installer, Pinion (Originally Shipped In Kit Number(s) 8887, 8887CC.) 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.) 9611 - Plug, Differential End (Originally Shipped In Kit Number(s) 9690.) 9612 - Installer, Bearing (Originally Shipped In Kit Number(s) 9690.) 9613 - Adapters, Puller (Originally Shipped In Kit Number(s) 9690, 9720-SUP.) C-293-PA - Puller, Press (Originally Shipped In Kit Number(s) 8418, 8837, C-293-M.) C-3095-A - Installer, Bearing 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.) D-146 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8667.) L-4438 - Dial Indicator Post

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Scheme 51: SPECIAL TOOLS
Scheme 51: SPECIAL TOOLS

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Scheme 68

Scheme 68: REMOVAL
Scheme 68: REMOVAL
  1. Remove the differential case from the housing.
  2. Install Plug (special tool #8888, Plug, Differential Bearing) (4) into the end of the case.
  3. Remove differential case bearings (3) with Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) (2) and Bridge (special tool #938, Bridge) (1).

Scheme 69

Scheme 69: INSTALLATION
Scheme 69: INSTALLATION
  1. Set differential case (2) on Plug (special tool #8888, Plug, Differential Bearing).
  2. Install differential case bearings (3) with Installer (special tool #8881, Installer, Bearing) (4) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
  3. Install differential case into housing.

Scheme 70

Scheme 70: REMOVAL
Scheme 70: REMOVAL
  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).

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Scheme 71: INSTALLATION
Scheme 71: INSTALLATION
  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.

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Scheme 72: REMOVAL
Scheme 72: REMOVAL

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Scheme 73
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  1. Remove differential housing cover and drain lubricant from the housing.
  2. Remove hub bearings and axle shafts.
  3. Remove adjuster lock bolts (1) and adjuster locks (2).
  4. Mark bearing caps (4) left and right for installation reference.
  5. Remove bearing cap bolts and remove bearing caps.
  6. Loosen differential bearing adjusters (2, 4) with a hammer and punch.
  7. Remove differential case from the housing.
  8. Remove bearing cups (1, 3) and tag them left and right for installation reference.

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Scheme 74: DISASSEMBLY
Scheme 74: DISASSEMBLY

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Scheme 76
  1. Remove pinion shaft lock bolt.
  2. Remove pinion shaft (1) from pinion gears (3) with a punch (2).
  3. Rotate differential pinion gears (2) to differential window (1) and remove pinion gears and thrust washers (3).
  4. Remove differential side gears (1) (2) and thrust washers.

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Scheme 77: ASSEMBLY
Scheme 77: ASSEMBLY

Note. If same gears and thrust washers are being used, install them into original locations.

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Scheme 78
Scheme 78
  1. Lubricate all differential components with axle lubricant.
  2. Install differential side gears (2) and thrust washers.
  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.).

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Scheme 79: INSTALLATION
Scheme 79: INSTALLATION

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Scheme 80
Scheme 80
  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.
  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.
  7. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
  8. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
  9. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
  10. Rotate the pinion several times to seat the differential bearings.
  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.
  13. Tighten pinion gear side adjuster an additional: New Bearings: 6 Adjuster Holes Original Bearings: 4 Adjuster Holes
  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»(ref-457780-S25335401782012030200000) for procedure.
  18. Install axle shafts and hub bearings.
  19. Install differential housing gasket and cover. Tighten cover bolts to 40 N.m (30 ft. lbs.).
  20. Fill differential with lubricant to specifications.
  21. Install fill plug and tighten to 32 N.m (24 ft. lbs.).

Scheme 81

Scheme 81: DESCRIPTION
Scheme 81: DESCRIPTION

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.

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