I do my own maintenance, Ive even rebuilt a few motors in my life time. But thats about my only experience working on vehicles. Transmissions and axels are my weak points. My axel needs rebuilding and very soon before it locks up on me. This all started over a year ago. I changed the rear axel lube and I found 2 of those c clips Ive been reading about. I just pulled them out and refilled the fluid and kept diving it as it was. Well after about 3 months I noticed small drips of lube on the carport just under the rear axel and saw that it was coming out from the carrier bearing. I guess the seal is had started going bad. I just kept driving it but made sure the fluid was always topped off. Weeks later I noticed a low noise from the rear that got louder and louder as the weeks went by.
I have an 2 wheel drive 02 Dodge Ram 1500 Quad cab Sport, with a manual trans. The axel is the corporate 9.25". I read the "sticky" tread of common issues and see that the mopar lsd clutch pack retainer clips are know for them falling out causing havoc. I hear that mopar did beef up the retainer clips and slowed down the problem; however, it still has been occurring. Ive asked a few of my mechanic friends about rebuilding this axel and they did have some experience but they said it's a pretty tuff job. One of they guys said it'd be easier just to swap out the whole axel from a salvage yard. I started looking around but these used axels are not cheep, even used. It got me wondering if the axels is a weak point for Dodge and this is a high failure LSD clutch assembly. Why buy something thats going to break again soon. I did price the repair and a few shops quoted me $1200 and thats only if the axels are good. If not it'd be way more. Not having the cash for the job I plan on doing it myself. I found a Ring Pinion Kit on eBay http://cgi.ebay.com/ebaymotors/ws/eB...ht_4468wt_1008 I just dont think it'd be a good idea to use the mopar LDS. Why not put in an aftermarket LSD clutch pack in like this Auburn Posi LDS thats on eBay http://cgi.ebay.com/ebaymotors/ws/eB...ht_7368wt_1002
Anyone have any luck with this LSD clutch pack? If because of a money shortage getting the original OEM New Posi will that get me another 50 + miles? http://cgi.ebay.com/ebaymotors/ws/eB...0#ht_542wt_941 Also, is the pinion kit and the lds all I need? what else would I need to complete the job? I really could use the advise.

 

You really need to inspect the carrier to determine what damage took place. It may be necessary to replace the entire carrier (or even axle) because you let it go for so long, but there is a good chance you will be ok since it hasn't completely failed yet.

The AAM 9.25" rear differential is actually quite strong when compared to Ford and GM 1/2 ton truck rear ends. The mopar ring and pinions are at least on par with most good aftermarket ones as far as strength and quality goes. It's simply the LSD that is the problem. IMO it's a POS even without the clip issue.

If you are replacing the ring and pinions and haven't done one, I'd suggest paying to have it done - it's a bi*ch to get the backlash right and if you f*ck it up just slightly, you've wasted your money and will be buying another ring and pinion. Some seasoned mechanics won't touch it and farm it out to axle shops.

Assuming your carrier is fine and you only need a ring & pinion, you are looking at ballpark $200 for the gears and $100 for an install kit. You can run open diff and stop right there if funds are low. A good, after-market LSD like an Auburn Gear ($450) or Detroit TruTrac ($550) can always be added later.

In your neck of the woods, 4 Wheel Parts on Colonial has a good gear man but they'll nail you on the parts and labor. Probably in the $900 range WITHOUT LSD.

Is a 4x4 specialty shop in Cocoa who I have sent guys to who do excellent work. I think about three members from here went there. Last I knew (about two years ago) they charged around $600 per axle for everything (gears, install kit & labor). I can turn you on to them if you are interested. Just let me know...

 

Yeah! That price is doable. Please send me their info. I understand thats a ballpark price giving if the axel I have is sill repairable. So, from what I understand your saying that if the axel assembly is still in pretty good condition it's ok to to have them just have them remove the LSD clutch pack so that it's not posi track? And just have them do the gear, bearing and seal's. The aftermarket LSD assemblies can be added later?

Thanks,
Doug

 

As Hammer said, I would replace the entire rear end. Maybe new axle seals at the end of the tubes and the guts of the diff like the carrier and bearings. Ive got the Auburn and I think Hammer does also.

As for rebuilding the stock LSD, check this link out.

http://www.off-roadweb.com/tech/1011...lok/index.html

An after market LSD can be added at any time but I personally would want them to rebuild my stock LSD and then later add an after market one and pay for the installation and setup all over again.

 

Thanks for the link. Thats a great pictorial view along with the instructions. With my limited cash flow Im leaning on doing the overhaul myself, the rebuilding link will come in handy. I wish they had gone into the backlash clearance a bit more, but hey, It is what it is. Maybe I can find a video on youtube that can help out on that process. WeedaHoe, I also downloaded the 03 Repair manual from your signature line. My truck is the 02 but it shouldn't be any different. That'll come in handy too, Thanks!!!

The main reason I had to park the truck was the radiator burst on the input tank. I found a place that refurbishes radiators but with limited means even 90 bucks was hard to come by, so I parked it. Maybe that was also a good thing because who knows? maybe, If I kept driving it the way it was the axel might just have locked up by now. So being that it's still roles maybe I'll have something to work with. But it's not all doom and gloom. Last week I got a call back from a prior employer wanting me back and this is the reason Im trying to get my ride back and road worthy.

Im still working on paying off the Truck, I have just one more year to go. Being unemployed over a year is what put me in this crazy bind. My truck had sit for over 6 months. Yesterday I went out to start her back up but the battery had died. I charged it without any luck so today I had to shuck out 90 bucks for a new battery at *****-mart. It's a good deal I guess being it's a 3 yr free replacement. Friday I'll be taking in the radiator and having it refurbished for $90.

I'll shop around for the clutches mentioned on the the LSD overhaul link. I may end up going with a pre assembled stock LSD carrier for $240 It comes already assembles with the clutches and spider gears. Then all thats left is the ring and pinion gear and the overhaul bearing and seal kit. I guess thats it. Oh, and the axel bearings and seals.

Ive found most of the items on eBay carrier and overhaul kits, but It's a place here orlando called Advance Driveline that gave me some good prices. I was surprised, they came pretty close to eBay prices on the carrier and overhaul kit. Good Deal

 

Found this guy on you tube pretty helpful.
http://www.youtube.com/watch?v=LObfe...e_gdata_player

Check out the damage on this 1st Gen Dodge. It's a good thing mine didnt get that bad. Ouch!
http://www.youtube.com/watch?v=_FZxRVBZGzg

 

btw thats a second gen dodge first gen was 93 and prior