2002 Dodge Ram 1500 4.7l Differential

limited slip differential

DIFFERENTIAL

REMOVAL

Do not use steam, kerosene or gasoline to clean the housing.
Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
Tag the differential bearing cups and threaded adjusters to indicate their location.

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.
4. Remove axle shafts.
5. Remove RWAL/ABS sensor from housing.
6. Mark differential housing and bearing caps for installation reference.
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.
10. Hold differential case while removing bearing caps and adjusters.
11. Remove differential case.

INSTALLATION

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instruction will result in a leak.
Be sure that all bearing cap bolts are tightened to their final torque of 136 N·m (100 ft. lbs.) before proceeding.
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.

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.
4. Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten lower bolts finger-tight until the bolt head is seated. Then perform the differential bearing preload and adjustment procedure.
5. Install axle shafts.
6. Apply a bead of orange Mopar™ Axle RTV Sealant or equivalent to the cover.
7. Install cover and any identification tag and tighten cover bolts to 41 N·m (30 ft. lbs.).
8. Fill differential with lubricant to specifications.

DIFFERENTIAL SIDE GEAR R&R

REMOVAL

Do not use steam, kerosene or gasoline to clean the housing.
Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
Tag the differential bearing cups and threaded adjusters to indicate their location.

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.
4. Remove axle shafts.
5. Remove RWAL/ABS sensor from housing.
6. Mark differential housing and bearing caps for installation reference.
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.
10. Hold differential case while removing bearing caps and adjusters.
11. Remove differential case.
12. Rotate both pinion gears with thrust washer to the differential window and remove both gears and thrust washers.
13. Remove differential side gears and thrust washers.

INSTALLATION

CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instruction will result in a leak.
Be sure that all bearing cap bolts are tightened to their final torque of 136 N·m (100 ft. lbs.) before proceeding.
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.

1. Lubricate all differential components with axle lubricant..
2. Install differential side gears and thrust washers through differential window.
3. Install both pinion gears with thrust washer into differential window and mate with the side gears. Rotate both pinion gears into the case.
4. Rotate gears to align hole in the pinion gears with hole in the differential case.
5. Slide pinion shaft into the case and through the pinion gears to align the gears.
6. 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.
7. Install differential assembly into the housing.
8. Install differential bearing caps in their original locations.
9. Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten lower bolts finger-tight until the bolt head is seated. Then perform the differential bearing preload and adjustment procedure.
10. Install axle shafts.
11. Apply a bead of orange Mopar™ Axle RTV Sealant or equivalent to the cover.
12. Install cover and any identification tag and tighten cover bolts to 41 N·m (30 ft. lbs.).
13. Fill differential with lubricant to specifications.