Case Assembly, Differential, Electric Locker: Installation: Installation
WARNING: This page is about a different car, the 2012 RAM Pickup and 2012 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.
- Lubricate differential case bearing.
- Install differential case with bearings cups into the housing.
- Slide electric locker connector through differential housing.
- Install O-ring on electric locker connector.
- Install electric locker connector (1) with retainer (2) in differential housing.
- Install connector retainer and bolt.
NOTE:
Do not torque bearing cap and bolts at this time.
- Install bearing caps (2) and tighten bearing cap bolts finger-tight.
- 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.
- 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.
- Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
- Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
- Tighten pinion gear side adjuster firmly against the differential case bearing cup.
- Rotate the pinion several times to seat the differential bearings.
- Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
- Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
- Tighten pinion gear side adjuster an additional:
- New Bearings: 6 Adjuster Holes
- Original Bearings: 4 Adjuster Holes
- Tighten bearing cap bolts (4) to 85 N.m (63 ft. lbs.).
- Install adjuster locks (2) and tighten bolts (3) to 25 N.m (18 ft. lbs.).
- Install axle shafts and hub bearings.
- Install sensor target magnet (1) on bearing cap.
- 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.
- 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 spec.
- Energize locker and set sensor air gap (2) to 5.05 mm ± 0.25 mm (0.20 in. ± 0.01 in.).
- 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.
- Hold right axle and rotate left axle until dog clutch engages with an audible click nose.
- 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.
- Measure ring gear backlash and check gear tooth contact pattern. For procedure, refer to ADJUSTMENTS .
- Install differential housing gasket and cover. Tighten cover bolts to 40 N.m (30 ft. lbs.).
- Fill differential with lubricant.
- Install fill plug and tighten to 32 N.m (24 ft. lbs.).