Front Axle - 9 1/4 Aa: Removal & Installation RAM Pickup 2500

INSTALLATION

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 (3), retainer clip and bolts.
5. Raise axle and align it with the spring pads.
6. Position upper (4) and lower control arms (5) in the axle brackets. Install bolts, nuts and align the suspension alignment cams to the reference marks. Do not tighten at this time.
7. Connect track bar (6) to the axle bracket and install the bolt. Do not tighten at this time.
8. Install shock absorber (2) and stabilizer bar (1)
9. Install drag link and tie rod to the steering knuckles.
10. Install ABS wheel speed sensors.
11. Install rotors and brake calipers.
12. Connect the axle vent hose.
13. Install front propeller shaft.
14. With vehicle on the ground, tighten upper control arm nuts at axle to 149 N.m (110 ft. lbs.). Tighten upper control arm nuts at frame to 149 N.m (110 ft. lbs.).
15. With vehicle on the ground, tighten lower control arm nuts at axle to 190 N.m (140 ft. lbs.). Tighten the lower control arm nuts at frame to 190 N.m (140 ft. lbs.).
16. Tighten track bar bolt at the axle bracket to 176 N.m (130 ft. lbs.).
17. Check front wheel alignment.

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. 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.
11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
13. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
14. Rotate the pinion several times to seat the differential bearings.
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.
17. Tighten pinion gear side adjuster an additional: New Bearings: 6 Adjuster Holes Original Bearings: 4 Adjuster Holes
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.).
20. Install axle shafts and hub bearings.
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 specification.
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»(ref-457780-S25335401782012030200000) 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.).

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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. 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.
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).
8. Hold pinion flange (1) with Flange Wrench (special tool #8979, Wrench, Pinion Flange) (2) and remove pinion flange nut and washer.
9. Remove pinion flange (1) from pinion with Pinion Flange Puller (special tool #8992, Remover, Pinion Flange) (2).
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.
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.

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1. Install front pinion bearing cup with Installer (special tool #D-146, Installer, Bearing Cup) (1) and Handle (special tool #C-4171, Driver Handle, Universal) (2).
2. Install rear 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.
3. Install pinion depth shim (1) on the pinion gear (2) shaft.
4. Install rear pinion bearing (4) with Installer (special tool #C-3095-A, Installer, Bearing) (2) and a press (1).
5. Install new collapsible spacer (1) on pinion gear (2).
6. Lubricate pinion and bearings (3).
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).
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.
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.

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1. Remove hub bearings and axle shafts.
2. Remove differential from differential housing (2).
3. Remove differential bearing adjusters (1).
4. Remove axle seals (2) located behind adjusters with Receiver (special tool #8498, Receiver, Axle Shaft Seal) and Extractor (special tool #6310, Remover, Bearing/Seal).
5. Install Receiver (special tool #8498, Receiver, Axle Shaft Seal) (1) into the adjuster bore.
6. Install Extractor Rod (special tool #6310, Remover, Bearing/Seal) with Extractor Foot (special tool #6310-9, Head) (2) through the receiver and axle seal.
7. Install Extractor Plate (special tool #6310-2, Disc) and Nut (special tool #6310-7, Nut) (2) on the extractor rod (1).
8. Tighten nut (2) on extractor rod (1) to pull seal into the receiver.

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1. Install axle seal on Installer Cups (special tool #8885-2, Assembly, Screw) (1) (3) and position cups with seals into the housing. NOTE: Seals are installed with the axle guide facing outward.
2. Install Turnbuckle (special tool #8885-1, Installer Seal Plate) (2) into installer cups and expand the turnbuckle until the seals bottom out in the housing.
3. Install adjuster (1) into the differential housing (2).
4. Install differential in housing.
5. Install axle shaft and hub bearings.

REMOVAL

1. Mark propeller shaft and pinion flange (1) for installation reference.
2. Remove propeller shaft.
3. Remove hub bearings and axle shafts.
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.
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).
9. Remove pinion seal with a seal puller.

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.
11. Install axle shafts and hub bearings.
12. Install propeller shaft with reference marks aligned.

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1. With the vehicle in neutral, position vehicle on hoist.
2. Remove brake caliper, rotor and ABS wheel speed sensor if equipped.
3. Remove axle shaft (2) cotter pin (3), hub nut (1) and washer.
4. Remove four hub bearing bolts (2) from the back of the steering knuckle.
5. Remove hub bearing from the steering knuckle.
6. Remove axle shaft (2) from steering knuckle (1) and axle housing.

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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.
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.
6. Install axle (2) washer and 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.).
9. Align nut to next cotter pin hole and install new cotter pin (3).

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Note. Saturate bearing caps with penetrating oil prior to removal.

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1. Remove axle shaft.
2. Remove bearing cap snap rings (1) from stub shaft yoke (2) bearing caps.
3. Position receiver/socket (2) and driver/socket (1) on stub shaft yoke (3) in press. Press bearing cup into receiver/socket (2).
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)
6. Remove bearing cap (1) from stub shaft yoke (2). Then remove stub shaft from U-joint cross.
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).
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)
11. 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 (1) until bearing cap snap ring groove is visible and install snap ring (2).
6. Position receiver/socket (1) on shaft yoke and driver/socket (2) on bearing cap in press.
7. Press bearing cap into shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2).
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 and driver/socket (2) on bearing cap in press.
11. Press bearing cap into stub shaft yoke (1) until bearing cap snap ring groove is visible and install snap ring (2).
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 (1) until bearing cap snap ring groove is visible and install snap ring (2).
14. Install axle shaft.