2001-2008 Dodge Ram 1500, 2500, 3500 Troubleshooting, Diagnosis, Testing, Inspection, Cleaning, Removal & Installation Procedures Download.

 TROUBLESHOOTING, DIAGNOSIS, TESTING & PART/PARTS REPAIR 1

 AXLE - 10 1/2 AA - INSTALLATION, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 AXLE - 10 1/2 AA - OPERATION, REAR . . . 3-100 AXLE - 10 1/2 AA - REMOVAL, REAR . . . . . 3-103 AXLE - 10 1/2 AA - SPECIAL TOOLS, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 AXLE - 10 1/2 AA - SPECIFICATIONS, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108 AXLE - 11 1/2 AA - ADJUSTMENTS, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131 AXLE - 11 1/2 AA - DESCRIPTION, REAR . . 3-127 AXLE - 11 1/2 AA - DIAGNOSIS AND TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . 3-127 AXLE - 11 1/2 AA - INSTALLATION, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130 AXLE - 11 1/2 AA - OPERATION, REAR . . . 3-127 AXLE - 11 1/2 AA - REMOVAL, REAR . . . . . 3-130 AXLE - 11 1/2 AA - SPECIAL TOOLS, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135 AXLE - 11 1/2 AA - SPECIFICATIONS, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135 AXLE - 9 1/4 - ADJUSTMENTS, REAR . . . . . 3-74 AXLE - 9 1/4 - DESCRIPTION, REAR . . . . . . 3-69 AXLE - 9 1/4 - DIAGNOSIS AND TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 3-69 AXLE - 9 1/4 - INSTALLATION, REAR . . . . . . 3-74 AXLE - 9 1/4 - OPERATION, REAR . . . . . . . . 3-69 AXLE - 9 1/4 - REMOVAL, REAR . . . . . . . . . . 3-74 AXLE - 9 1/4 - SPECIAL TOOLS, REAR . . . . . 3-80 AXLE - 9 1/4 - SPECIFICATIONS, REAR . . . . . . 3-79 AXLE - 9 1/4 AA - ADJUSTMENTS, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 AXLE - 9 1/4 AA - DESCRIPTION, FRONT . . . 3-45 AXLE - 9 1/4 AA - DIAGNOSIS AND TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . . 3-45 AXLE - 9 1/4 AA - INSTALLATION, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 AXLE - 9 1/4 AA - OPERATION, FRONT . . . . 3-45 AXLE - 9 1/4 AA - REMOVAL, FRONT . . . . . . 3-48 AXLE - 9 1/4 AA - SPECIAL TOOLS, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 AXLE - 9 1/4 AA - SPECIFICATIONS, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 AXLE - C205F - ADJUSTMENTS, FRONT . . . . 3-21 AXLE - C205F - DESCRIPTION, FRONT . . . . . 3-18 AXLE - C205F - DIAGNOSIS AND TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . . 3-18 AXLE - C205F - INSTALLATION, FRONT . . . . 3-21 AXLE - C205F - OPERATION, FRONT . . . . . . 3-18 AXLE - C205F - REMOVAL, FRONT . . . . . . . . 3-21 AXLE - C205F - SPECIAL TOOLS, FRONT . . . 3-30 AXLE - C205F - SPECIFICATIONS, FRONT . . . 3-29 AXLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . 0-4 AXLE BEARINGS - INSTALLATION . . 3-112,3-139, 3-34,3-84 AXLE BEARINGS - REMOVAL . . 3-112,3-138,3-33, 3-84 AXLE SHAFT SEALS - INSTALLATION . 3-33,3-58, 3-84 AXLE SHAFT SEALS - REMOVAL . 3-33,3-58,3-84 AXLE SHAFTS - ASSEMBLY . . . . . . . . . . . . . 3-58 AXLE SHAFTS - DISASSEMBLY . . . . . . . . . . . 3-56 AXLE SHAFTS - INSTALLATION . . . . 3-111,3-138, 3-33,3-58,3-83 AXLE SHAFTS - REMOVAL . . . . 3-111,3-138,3-33, 3-56,3-83 BACK - INSTALLATION, CENTER ARMREST / SEAT . . . . . . . . . . . . . . . . . . . . 23-78 BACK - REAR - INSTALLATION, SEAT . . . . . 23-84 BACK - REAR - REMOVAL, SEAT . . . . . . . . 23-84 BACK - REMOVAL, CENTER ARMREST / SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-77 BACK CUSHION / COVER - FRONT - INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 23-83 BACK CUSHION / COVER - FRONT - REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 23-83 BACK CUSHION / COVER - REAR - INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 23-85 BACK CUSHION / COVER - REAR - REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 23-85 BACK HINGE - INSTALLATION, CENTER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-80 BACK HINGE - REMOVAL, CENTER SEAT . . 23-79 BACK INERTIA HINGE COVER - INSTALLATION, CENTER SEAT . . . . . . . . . . 23-78 BACK INERTIA HINGE COVER - REMOVAL, CENTER SEAT . . . . . . . . . . . . . . 23-78

 DIAGNOSIS AND TESTING LOW LUBRICANT LEVEL   A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or an incorrect lubricant level check. Leaks can occur at the mating surfaces of the gear case, adaptor or extension housing, or from the front/rear seals. A suspected leak could also be the result of an overfill condition. Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening or use of a non-recommended sealer. A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the clutch disc causing the disc to slip, grab and or chatter. A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition. HARD SHIFTING Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants. The consequence of using non-recommended lubricants is noise, excessive wear, internal bind and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise. Shift component damage or damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Worn/damaged pressure plate or disc can cause incorrect release. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases this condition will decline as the rings wear-in. TRANSMISSION NOISE   Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds.

 DIAGNOSIS AND TESTING - PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. (1) Inspect tires for size, air pressure and tread wear. (2) Inspect front wheel bearings for wear. (3) Inspect front wheels for excessive radial or lateral runout and balance. (4) Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. (5) Inspect suspension components for wear and noise. (6) On 4x4 vehicles check suspension height (LD only). (7) Road test the vehicle.