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Expert
133 Answers
- Posted on Jan 23, 2009
Re: want to install a posi unit in my 2004 Ram Quad 2WD...
REMOVAL
- Remove filler plug from the differential cover.
- Remove differential cover and drain the lubricant.
- 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.
- Remove axle shafts.
- Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
- Mark differential housing and bearing caps for installation reference (REFERENCE MARKS).
- Remove bearing threaded adjuster lock from each bearing cap.
- Loosen differential bearing cap bolts.
- Loosen differential bearing adjusters through the axle tubes with Wrench C-4164 (THREADED ADJUSTER TOOL).
- Hold differential case while removing bearing caps and adjusters.
- Remove differential case.
NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.
INSTALLATION
- 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.
- Install differential assembly into the housing.
- Install differential bearing caps in their original locations (BEARING CAPS).
- 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.
- 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.
- Install axle shafts.
- 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.
- Install the cover and any identification tag and tighten cover bolts to 41 N·m (30 ft. lbs.).
- 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.
- 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.
- 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.
- 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.
- 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.
- Tighten the differential bearing cap bolts 136 N·m (100 ft. lbs.).
- 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.)
- Measure the ring gear backlash. The range of backlash is 0.15 to 0.203 mm (0.006 to 0.008 in.).
- 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.
- 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.
- Install the threaded adjuster locks and tighten the lock screws to 10 N·m (90 in. lbs.).
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