2005 Ram 2500 Free Spin Install & Other Goodies

[legopnuematic]

Cleaned the tapers out and installed knuckles on ball joints per EMF's directions.

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Couple of dings on the spindles. I'll be honest not thrilled about that at the price point these are at, maybe that is just me being a machinist, I can be pretty critical of stuff like that. But filed the mating surfaces to ensure they will be flat.

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Axle shafts slid in, dust shield and spindle installed with anti seize.

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New NTK wheel speed sensors, the old ones worked, but the wires had some melted spots in them so decided to go new. Spindles torqued and should be ready to receive the hubs once those are prepped.

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[legopnuematic]

Studs pressed in

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In the machining trade, this is called the Tennessee floor finish. You know, they could cut their cycle time a lot by using a 3" face mill. Anything is better than a 1/2" endmill...

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But all on now. Now just put rotors/calipers back on and reconnect steering, install front cover ane fill with fluid.

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[nvrenuf]

Everything looks great. I didn’t realize the rotors were still loose in these kits, I just assumed (I know…) they were retained by the studs like older axles.

 

[legopnuematic]

Everything looks great. I didn’t realize the rotors were still loose in these kits, I just assumed (I know…) they were retained by the studs like older axles.

Yes, afaik, all of the kits for the 2000+ trucks retain the outboard/slip on rotor feature.

I know the 94-99 Dana 60 kits keep the rotors inboarded. Fun fact is the 94-99 Rams use the same calipers as a lot of GMT400 trucks and other GMs of the era.

 

[legopnuematic]

Attempted to powder coat the front cover. Came out decent except for a couple spots, not sure if it was contamination or something in the process that caused it. Oh well. Good enuf'

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[legopnuematic]

Got the rear torn apart. Axles pulled, carrier removed. Removed the ring gear, the tone ring is pressed onto the carrier, to remove it I used the same method to remove ring gears from flywheels. Spin the carrier and heat with torch, about a minute later it fell right off.

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Will be receiving new hub seals. These are a nicer design than my Dana 70 is as the are a 2 piece design, so the axle is not a wear surface.

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[legopnuematic]

Assembled the service cart I had picked up and put it into service.

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Cover installed with new hardware and lube locker gasket and filled with fresh gear oil.

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Cleaned and prepped the ring gear, tone ring, and carrier for the rear. Put the ring gear in the oven to slip it onto the carrier.

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Then after it cooled with the bolts started and shrunk onto the carrier, ran them down, setup in the press to hold it to torque the ring gear bolts. Then pressed the carrier bearings on.

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[legopnuematic]

With the bearings pressed on, I cleaned and lubed one new race, set the carrier on the race, then tone ring into the oven to drop it on the carrier. That way I could tap it with a brass drift while spinning it to be sure it's up against the ring gear.

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Waiting on a new o ring for the rear mag hytec cover. Cleaning up the ancillary components as well, adjusters, caps, bolts, etc.

So the front is done now, filled with gear oil and ball joints greased. Rear is moving towards install. Need to pull the rear hubs to do the seals yet.

 

[legopnuematic]

On Friday after work kind of had an oopsie. Managed to have the carrier slip out of my hands while trying to get it in the housing and it rolled down me and to the floor. Thankfully the only damage (besides the tone ring leaving its mark on me) was one bearing. We were able to get another Timken overnighted. All in all could have been much worse.

Removed the cage from the damaged bearing after removal and found some Brinelling on the inner race.

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And made a meme of the situation because why not

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On Saturday, we got the new bearing and headed up, got it installed and came up with a better way (safer) to get the carrier installed. 2nd time worked out without incident.

Frownie face in the cardboard lol.

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Got the adjusters moved in and was able to begin to get the backlash set. Got it close to about .009 (was .008 when we took it apart).

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Made sure to preload the carrier sufficiently, tightened the caps a little more, brought the lash back to the .008, excellent.

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[legopnuematic]

With the caps torqued, rechecked the lash one final time before. Still where I wanted it so we could continue with the reassembly.

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Pulled the rear hubs and changed the wheel seals, reinstalled and set to spec, axle shafts reinstalled.

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The new cart is working as intended.

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Wheels back on.

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It moves!

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[legopnuematic]

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Made the drive into town to eat some Mexican food.

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And drove back home without issues.

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What will be the next thing to fill the void??

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[WebMonkey]

very nice!

if you really need a project;
my 2005 1/2 ton quad cab (daily) could use some love.

it's pw7 white too!

'monkey

 

[CountKrunk]

Great job man!

 

[legopnuematic]

very nice!

if you really need a project;
my 2005 1/2 ton quad cab (daily) could use some love.

it's pw7 white too!

'monkey

Thank you, I'm pretty well in for projects at the moment, but you never know. What kind of love does it need lol? What part of the Ozarks are you in?

Great job man!

Thank you! It was a fun project, a learning experience for me in some regards as it was my first time messing with manual locking hubs, rather clever how they work.