Download 1981-1992 DODGE RAMCHARGER Service and Repair Manual –

Overhauling the gear set on a Dodge Ramcharger involves disassembling and reassembling the differential, which is a complex process but can be tackled with patience and the right tools. click here for more details on the download manual…..

Here’s a simplified step-by-step guide to help you understand the process. Please note that this is a general overview; consult a repair manual or a professional for specific details and safety precautions.

### Tools and Materials You’ll Need:
– Basic hand tools (wrenches, sockets, screwdrivers)
– Torque wrench
– Gear puller
– Differential rebuild kit (includes bearings, seals, and gaskets)
– Gear oil
– Cleaning supplies (brake cleaner, rags)
– Safety glasses and gloves

### Step-by-Step Guide:

#### 1. **Preparation:**
– **Safety First:** Make sure you wear safety glasses and gloves to protect yourself.
– **Gather Tools:** Collect all necessary tools and materials.
– **Work Area:** Set up a clean and well-lit workspace.

#### 2. **Remove the Differential Cover:**
– **Lift the Vehicle:** Use jack stands to safely lift the vehicle.
– **Drain the Oil:** Place a drain pan under the differential and remove the cover bolts to drain the old gear oil.
– **Remove the Cover:** Gently tap the cover with a rubber mallet if it’s stuck. Clean the mating surfaces after removal.

#### 3. **Remove the Axles:**
– **Take Out the C-clips:** If applicable, remove C-clips holding the axle shafts in place, typically located inside the differential.
– **Pull Out the Axles:** Gently pull the axles out of the differential housing.

#### 4. **Disassemble the Differential:**
– **Remove the Pinion Gear:** Use a socket to remove the pinion gear nut and then pull the pinion gear out.
– **Remove the Carrier:** Take out the differential carrier by removing the bolts holding it in place. Be cautious as it may be heavy.

#### 5. **Inspect Components:**
– **Check Gears and Bearings:** look for wear or damage on the gears and bearings. Replace any worn parts with those from your rebuild kit.

#### 6. **Install New Components:**
– **Install New Bearings:** Press new bearings onto the pinion and carrier (you may need a press for this).
– **Reassemble the Carrier:** Place the carrier back into the housing and secure it with bolts.
– **Install the Pinion Gear:** Reinsert the pinion gear and tighten the nut to the specified torque using a torque wrench.

#### 7. **Adjust Backlash and Preload:**
– **Check Gear Mesh:** Use a marking compound to check the gear mesh pattern. Adjust the shims as necessary to achieve the proper backlash (the space between the gears).
– **Set Preload:** Ensure the bearings are properly preloaded to avoid excessive wear.

#### 8. **Reinstall the Axles:**
– **Insert Axles:** Slide the axles back into the differential housing and secure them with C-clips if applicable.

#### 9. **Reattach the Differential Cover:**
– **Clean Surfaces:** Ensure the mating surfaces are clean and free of debris.
– **Apply Gasket Maker:** If using a gasket maker, apply it to one surface of the differential cover.
– **Reinstall the Cover:** Bolt the differential cover back in place.

#### 10. **Fill with Gear Oil:**
– **Add Gear Oil:** Use a funnel to fill the differential with the appropriate type download DODGE RAMCHARGER workshop manual and amount of gear oil, as specified in the owner’s manual.

#### 11. **Lower the Vehicle:**
– **Remove Jack Stands:** Carefully lower the vehicle back to the ground.

#### 12. **Test Drive:**
– **Check for Issues:** After a short test drive, listen for any unusual noises and check for leaks around the differential cover.

### Conclusion:
Overhauling a gear set can be a rewarding project, but it requires careful attention to detail and patience. If at any point you’re unsure, don’t hesitate to consult a professional mechanic or refer to a detailed repair manual specific to your Dodge Ramcharger model.
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