The HD 1080P high resolution video follows the magazine's
highly popular 11.5" AAM
axle rebuild article that features 128 illustrated
steps! If you want that kind of insight into rebuilding a 9.25" AAM axle—or changing
out the ring-and-pinion gears after you lift your truck and install oversized tires—then
take the time to watch this HD video!—Moses Ludel
For those who have sufficient
bandwidth, open this video to full-screen, 1080P viewing for
maximum impact and detail!
For over a decade, the AAM 9.25" and 11.5" axles have been a mainstay for G.M. and Chrysler's Dodge
Ram trucks. The magazine's comprehensive step-by-step rebuild of an 11.5" axle has proven to be a
, featuring 128 color-illustrated, captioned and tightly detailed
Learn quick, safe methods for disassembling the front axle and removing the differential carrier. View
the video at full-screen 1080P mode for detail!
The 11.5" coverage focused on the 4.56 ring-and-pinion gear changeout on the magazine's 2005 Dodge
Ram 3500 4WD pickup. This HD video close-up is the same truck's front axle, undergoing a ring-and-pinion
gear changeout. Follow the coverage and the high resolution video. Review the popular 11.5" AAM
axle rebuild article
—found exclusively here at the magazine!
Improvising on tools can save cost and provide a high degree of accuracy during the setup
of the ring-and-pinion gears and bearing preloads. Find out how the original bearings and crush sleeve, in good
condition, can become useful "tools".
Removing and installing a ring gear takes care and orderly steps. At right, the new ring
gear pulls readily onto the clean differential carrier after heat soaking the ring gear in the parts washing
cabinet. The cabinet solution, pumped at 140-150 degrees F, heats the gear substantially in just ten minutes of
At left, the old crush sleeve, pinion flange washer and modified old pinion nut serve as
a "puller" for drawing the new pinion gear's shaft through the nose end of the new pinion bearing. At right is
the Miller/SPX 8883A special spanner designed for rotating the adjuster rings on a 9.25" or 11.5" AAM
differential carrier during fit-up. Bearing preload is generally 4-6 notches tighter than zero play. Carrier
bearing preload is also measurable as pinion gear rotational resistance...See the video for details!
Tooth contact patterns can indicate pinion gear depth in the housing, ring-and-pinion
backlash, ring gear runout and gear alignment. For quick backlash checks, the dial indicator (at right) with
magnetic stand is the professional tool of choice. Backlash on the 9.25" AAM axle is 0.005"-0.007". These
ring-and-pinion gears have been set to 0.005"-0.0055"—after run-in, backlash should be 0.006". The axle will
run quietly, without backlash noise, yet not run hot nor suffer from excessive friction.
One method for tie-rod end (left) tightening, according to the 2005 Dodge Ram 2500/3500
factory shop manual, is described in the video (top of page): Torque the nut to 40 ft-lbs then tighten the nut
another 90-degrees. The flange base, Nylock nut feels very secure at this torque setting...If you detach the
caliper adapters to remove the rotors, the two anchor bolts at each side require clean threads, Loctite 242 and
a torque of 250 ft-lbs for HD truck models and 130 ft-lbs for LD truck models. This means time for accurate air
impact tools on the HD models!
Axle differential cover has been scoured thoroughly, then painted on the outside with a
durable, corrosion resistant ceramic engine paint. Bolts are clean with Loctite 242 on threads, torqued to 30
ft-lbs. At right, 75W-140 synthetic Mopar axle lube is our gear lubricant of choice. 75W-90 Mopar
synthetic lube would also be acceptable for most driving conditions. The 140-wt.* factor is for summer trailer
*Note: 75W-140 does not mean the oil "thickens" to 140 weight cold
pour thickness when hot. It simply has the same viscosity or ability to lubricate as a 140 wt. at that higher
heat. 75W-140 provides a wide range of protection yet pours like a 75W when cold to assure adequate lube and
flow in temperatures that require a 75W. G.M. and Dodge-Ram do recommend 75W-90 for this gear assembly, so if
you are more comfortable with that oil, make sure it is synthetic with high temperature tolerance. At severely
high temperatures, 75W-90 offers less viscosity protection than 75W-140...See break-in details at the
11.5" AAM axle
Learn details about AAM
axle building demands in the HD video (above) and the 11.5" AAM axle
rebuilding how-to article
at the magazine!