Question about 2004 Dodge Ram 1500

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Want to install a posi unit in my 2004 Ram Quad 2WD 9.25

Need info on installation of an aftermarket posi unit in my 04 Ram Quad 2WD. I have found one and would like some advice on removal and installation. I have never done one before and don't want to make a costly mistake..

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REMOVAL

  1. Remove filler plug from the differential cover.
  2. Remove differential cover and drain the lubricant.
  3. Clean housing cavity with flushing oil, light engine oil or a lint free cloth. NOTE: Do not use steam, kerosene or gasoline to clean the housing.
  4. Remove axle shafts.
  5. Remove RWAL/ABS sensor from housing. NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
  6. Mark differential housing and bearing caps for installation reference (REFERENCE MARKS).
  7. Remove bearing threaded adjuster lock from each bearing cap.
  8. Loosen differential bearing cap bolts.
  9. Loosen differential bearing adjusters through the axle tubes with Wrench C-4164 (THREADED ADJUSTER TOOL).
  10. Hold differential case while removing bearing caps and adjusters.
  11. Remove differential case. NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.

INSTALLATION
  1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position.
  2. Install differential assembly into the housing.
  3. Install differential bearing caps in their original locations (BEARING CAPS).
  4. Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.
  5. Perform the differential bearing preload and adjustment procedure. NOTE: Be sure that all bearing cap bolts are tightened to their final torque of 136 N·m (100 ft.lbs.) before proceeding.
  6. Install axle shafts.
  7. Apply a bead of orange Mopar Axle RTV Sealant or equivalent to the housing cover (COVER SEALANT). CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
  8. Install the cover and any identification tag and tighten cover bolts to 41 N·m (30 ft. lbs.).
  9. Fill differential with lubricant to bottom of the fill plug hole. Refer to the Lubricant Specifications for the correct quantity and type. NOTE: Trac-lok™ differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.
DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash:
  • The maximum ring gear backlash variation is 0.076 mm (0.003 in.).
  • Mark the gears so the same teeth are meshed during all backlash measurements.
  • Maintain the torque while adjusting the bearing preload and ring gear backlash.
  • Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure. Insufficient adjuster torque can result in excessive differential case free-play and ring gear noise.
  • Insufficient adjuster torque will not support the ring gear correctly and can cause excessive differential case free-play and ring gear noise.
NOTE: The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. To ensure accurate bearing cup responses to the adjustments:
  • Maintain the gear teeth engaged (meshed) as marked.
  • The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth.
  • Do this five to ten times each time the threaded adjusters are adjusted.

  1. Through the axle tube use Wrench C-4164 to adjust each threaded adjuster inward until the differential bearing free-play is eliminated. Allow some ring gear backlash approximately 0.25 mm (0.01 in.) between the ring and pinion gear. Seat the bearing cups with the procedure described above.
  2. Install dial indicator and position the plunger against the drive side of a ring gear tooth (RING GEAR BACKLASH). Measure the backlash at 4 positions, 90 degrees apart around the ring gear. Locate and mark the area of minimum backlash.
  3. Rotate the ring gear to the position of the least backlash. Mark the gear so that all future backlash measurements will be taken with the same gear teeth meshed.
  4. Loosen the right-side, tighten the left-side threaded adjuster. Obtain backlash of 0.076 to 0.102 mm (0.003-0.004 in.) with each adjuster tightened to 14 N·m (10 ft. lbs.). Seat the bearing cups with the procedure described above.
  5. Tighten the differential bearing cap bolts 136 N·m (100 ft. lbs.).
  6. Tighten the right-side threaded adjuster to 102 N·m (75 ft. lbs.). Seat the bearing cups with the procedure described above. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft. lbs.)
  7. Measure the ring gear backlash. The range of backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).
  8. Continue increasing the torque at the right-side threaded adjuster until the specified backlash is obtained. NOTE: The left-side threaded adjuster torque should have approximately 102 N·m (75 ft. lbs.). If the torque is considerably less, the complete adjustment procedure must be repeated.
  9. Tighten the left-side threaded adjuster until 102 N·m (75 ft. lbs.) torque is indicated. Seat the bearing rollers with the procedure described above. Do this until the torque remains constant.
  10. Install the threaded adjuster locks and tighten the lock screws to 10 N·m (90 in. lbs.).

Posted on Jan 23, 2009

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SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Axle Shaft Removal
  1. Raise and support the vehicle. For additional information, refer to Section 100-02 .
  1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
  1. Remove the rear brake disc (2C026). For additional information, refer to Section 206-04 .
  1. Remove the differential housing cover (4033) and drain the lubricant. For additional information, refer to Differential Housing Cover in this section.
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    1. Remove the differential pinion shaft lock bolt (4241).
    1. Remove the differential pinion shaft.
  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the rubber O-ring in the axle shaft groove.
    Remove the U-washer (4N237).
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  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Damage to the rear brake anti-lock sensor (2C190) may occur if it is not removed before the axle shaft.
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  1. s3b~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Do not damage the wheel bearing oil seal.
    Remove the axle shaft.
--------------------------------------------------------------------------------------
Rear Wheel Bearing and Axle Shaft Oil Seal Removal
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  1. Using the special tools, install the new wheel bearing oil seal.
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-------------------------------------------------------------------
Installation
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    Install the U-washer.
    1. Position the two U-washers on the button end of the axle shaft.
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