Replace the ring and pinion gears in the rear differential of a 2014 Ram 2500 with 6.7L Cummins diesel engine, including complete differential disassembly, gear setup, and proper bearing preload adjustment.

Warnings

Tools required

Parts

• Ring and pinion gear set (specify gear ratio) × 1 — Use OEM specification
• Pinion bearing kit (includes inner/outer bearings and races) × 1 — Use OEM specification
• Carrier bearing set × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Pinion crush sleeve × 1 — Use OEM specification
• Differential cover gasket or RTV silicone × 1 — Mopar or equivalent
• Ring gear bolts × 1 — Use OEM specification
• Pinion nut × 1 — Use OEM specification
• Gear marking compound × 1 — Use OEM specification

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support securely on jack stands at frame rails
5. Remove rear wheels
6. Place drain pan under differential
7. Mark driveshaft and pinion flange orientation for reassembly alignment
8. Take reference photos of all components before disassembly

Procedure

1. 1

   Drain differential and remove cover
   Remove the differential cover bolts in a crisscross pattern. Allow gear oil to drain completely into drain pan. Once drained, remove cover completely and clean all old gasket material from housing and cover using gasket scraper. Inspect drained fluid for metal particles indicating previous gear damage.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Remove driveshaft
   Remove the four U-joint strap bolts at the pinion flange. Support driveshaft and carefully slide it rearward out of the differential. Plug the transmission/transfer case output with a rag to prevent fluid loss. Secure driveshaft out of the way.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Mark and measure pinion depth
   Before disassembly, use dial indicator to measure and record pinion depth from the carrier centerline. Rotate pinion and measure bearing preload using inch-pound torque wrench (should be 15-25 in-lbs for used bearings). Record all measurements. Mark the relationship between pinion nut, pinion shaft, and companion flange with paint pen for reference.
   ℹ️These measurements are critical for establishing baseline setup and verifying new gear installation.
4. 4

   Remove pinion nut and flange
   Using pinion holding tool to prevent rotation, remove the pinion nut with breaker bar or impact wrench. Remove companion flange using appropriate puller. Do not pry or hammer on flange as this can damage pinion bearings. Remove pinion seal and discard.
   ⚠The pinion nut is under significant tension from crush sleeve. Control removal to prevent sudden release.
5. 5

   Remove pinion gear assembly
   Carefully tap pinion shaft from the front to drive it out the rear of the housing. Catch the pinion gear, crush sleeve, inner bearing, and any shims as they come free. Remove outer pinion bearing race from housing using bearing puller or press. Keep all shims and measure/record their thickness. Remove inner bearing race from housing.
   ℹ️Crush sleeve will be damaged during removal and must be replaced. Do not attempt to reuse.
6. 6

   Remove differential carrier assembly
   Remove carrier bearing cap bolts and mark caps for proper orientation (passenger/driver side). Use pry bar to carefully work carrier assembly out of housing. Keep carrier bearings with their respective races if planning to inspect pattern. Place carrier assembly on clean workbench.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
7. 7

   Remove ring gear from carrier
   Mark ring gear orientation to carrier. Remove ring gear bolts (left-hand thread - turn clockwise to remove). If bolts are difficult to remove, apply penetrating oil and use impact wrench. Tap ring gear with soft mallet to separate from carrier. Clean all surfaces thoroughly.
   ⚠Ring gear bolts are left-hand thread. Turn clockwise to loosen.
8. 8

   Install new pinion bearings and races
   Using hydraulic press or bearing race installer, install new inner and outer pinion bearing races into differential housing. Ensure races are fully seated and square. Press new inner and outer pinion bearings onto pinion shaft using appropriate bearing installer tools. Verify new pinion gear depth marking on gear head and compare to old gear.
   ⚠Bearing races must be installed completely square and fully seated to avoid binding or preload issues.
9. 9

   Set pinion depth
   Using pinion depth setting tools and dial indicator, determine correct shim thickness for new pinion gear. Install calculated shims behind inner pinion bearing race. This process may require multiple measurements and shim adjustments. Reference pinion depth code stamped on pinion gear head (typically +/- number in hundredths of mm). Adjust shim thickness accordingly from nominal setup.
   ℹ️Pinion depth is the most critical measurement for proper gear contact pattern. Take time to get this correct before final assembly.
10. 10

    Install pinion gear with preload
    Lubricate pinion bearings with gear oil. Install pinion assembly into housing with inner bearing, new crush sleeve, and outer bearing. Install companion flange and new pinion nut. Gradually tighten pinion nut while rotating pinion to seat bearings. Check rotating torque frequently with inch-pound torque wrench. Target preload is 20-30 in-lbs for new bearings. Once crush sleeve begins to compress, tighten in small increments (1/16 turn) and recheck after each adjustment.
    ⚠️Do not over-tighten pinion nut. If you exceed target preload, crush sleeve must be replaced and process restarted. There is no backing off the nut.
11. 11

    Install ring gear on carrier
    Clean carrier and ring gear mating surfaces thoroughly. Align new ring gear to carrier, ensuring proper orientation. Apply thread locker to new ring gear bolts (left-hand thread). Install bolts hand-tight, then torque in progressive steps to manufacturer specification using star pattern (typically 85-120 lb-ft depending on axle). Verify gear is seated fully against carrier.
    ⚠Ring gear bolts are left-hand thread. Turn counter-clockwise to tighten.
12. 12

    Install carrier bearings and set backlash
    Press new carrier bearings onto carrier hubs if replacing. Install carrier assembly into housing with appropriate shims on each side. Install bearing caps in correct orientation. Gradually tighten bearing cap bolts while checking ring gear backlash with dial indicator at ring gear teeth. Adjust side shims to achieve 0.005-0.008 inch backlash. Moving shims from one side to other changes backlash without affecting bearing preload significantly. Once backlash is correct, verify carrier bearing preload.
    ℹ️Backlash adjustment requires patience. Small shim changes make significant differences in backlash measurement.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
13. 13

    Check gear contact pattern
    Apply gear marking compound to several ring gear teeth. Rotate pinion through several revolutions in both directions with light drag applied to ring gear. Examine contact pattern on coast and drive sides of teeth. Pattern should be centered on tooth face with slight bias toward toe. Adjust pinion depth if pattern is too high or low on tooth. Adjust backlash if pattern is too far toward toe or heel. Repeat marking and adjustment until pattern is correct.
    ⚠Incorrect gear pattern will cause noise and premature failure. Do not skip this verification step.
14. 14

    Install new pinion seal
    Clean pinion flange and seal bore thoroughly. Lubricate new pinion seal lip with gear oil. Using seal installer or large socket, carefully drive seal into housing until fully seated and flush. Do not cock seal during installation. Install companion flange, ensuring it is fully seated on pinion shaft splines.
    ⚠Do not disturb pinion nut or preload during seal installation. Work carefully to avoid rotating pinion.
15. 15

    Reinstall driveshaft and differential cover
    Align driveshaft to pinion flange using reference marks made during disassembly. Install U-joint strap bolts and torque evenly. Clean differential cover and housing mating surfaces. Apply new gasket or RTV silicone bead (1/4 inch). Install cover and torque bolts in crisscross pattern. Fill differential with 2 quarts Mopar 75W-140 synthetic gear lubricant through fill hole until fluid reaches bottom of fill plug hole.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    Differential Cover Bolts35 Nm (26 lb-ft)

Reassembly

1. Install rear wheels and hand-tighten lug nuts
2. Lower vehicle to ground
3. Torque wheel lug nuts to specification in star pattern
4. Test drive vehicle and listen for abnormal differential noise
5. Recheck differential fluid level after test drive and top off if needed
6. Check for any leaks around pinion seal and differential cover

Verification

• Test drive vehicle at various speeds and listen for whine, howl, or clunking from differential
• Perform figure-8 turns in both directions to load gears and verify quiet operation
• Check for leaks around pinion seal and differential cover after 50-100 miles
• Verify no vibration from driveshaft (indicates proper U-joint alignment)
• After 500 miles, drain and inspect gear oil for metal particles indicating improper setup
• Proper setup should result in quiet operation with no abnormal noise during acceleration, deceleration, or coasting

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