Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2006 Dodge and Ram Sprinter 2500 L5-2.7L DSL TurboFACTORY OEM SERVICE PROCEDURE
Disassembly and Assembly
DISASSEMBLY - SINGLE REAR WHEEL
1. Remove differential cover bolts and remove cover (Fig. 33).
2. Remove upper differential side gear (1) and shim (2) (Fig. 34).
3. Remove first set of differential pinion gears (1), spherical washers and mate shaft (2) (Fig. 35).
4. Remove second set of differential pinion gears (2), spherical washers and mate shaft (1) (Fig. 36).
5. Remove lower differential side gear (1) and shim (Fig. 37).
DISASSEMBLY - DUAL REAR WHEEL
1. Remove differential cover bolts and remove cover (Fig. 38).
2. Remove upper differential side gear (1) and shim (2) (Fig. 39).
3. Remove differential cross shaft (1) with pinion gears (2) and spherical washers (3) (Fig. 40).
4. Remove lower differential side gear (1) and shim (Fig. 41).
ASSEMBLY
ASSEMBLY - SINGLE REAR WHEEL
1. Install lower differential side gear (1) and shim (Fig. 42).
2. Install first differential pinions gears (1) with spherical washers and mate shaft (2) (Fig. 43).
3. Install second pinion gears (2) with spherical washers and mate shaft (1) (Fig. 44).
4. Install upper differential side gear (1) and shim (2) (Fig. 45).
5. Install differential cover with location numbers (1) on differential case (2) aligned (Fig. 46).
6. Install differential cover (2) bolts (1) and tighten to 45 Nm (33 ft. lbs.) (Fig. 47).
7. Check torque to rotate the differential gears with Torque Tool 9744 and a torque wrench. Torque should be 20-40 Nm (15-30 ft. lbs.).
NOTE: Shims are available in 0.05 mm (0.002 in.) increments, in thicknesses from 1.30 - 2.00 mm (0.051 - 0.078 in.).
ASSEMBLY - DUAL REAR WHEEL
1. Install lower differential side gear (1) and shim (Fig. 48).
2. Install first differential pinions gears (2) with spherical washers (3) and cross shaft (1) (Fig. 49).
3. Install upper differential side gear (1) and shim (2) (Fig. 50).
4. Install differential cover with location numbers (1) on differential case (2) aligned (Fig. 51).
5. Install differential cover (2) bolts (1) and tighen to 45 Nm (33 ft. lbs.) (Fig. 52).
1. Remove differential cover bolts and remove cover (Fig. 33).
2. Remove upper differential side gear (1) and shim (2) (Fig. 34).
3. Remove first set of differential pinion gears (1), spherical washers and mate shaft (2) (Fig. 35).
4. Remove second set of differential pinion gears (2), spherical washers and mate shaft (1) (Fig. 36).
5. Remove lower differential side gear (1) and shim (Fig. 37).
DISASSEMBLY - DUAL REAR WHEEL
1. Remove differential cover bolts and remove cover (Fig. 38).
2. Remove upper differential side gear (1) and shim (2) (Fig. 39).
3. Remove differential cross shaft (1) with pinion gears (2) and spherical washers (3) (Fig. 40).
4. Remove lower differential side gear (1) and shim (Fig. 41).
ASSEMBLY
ASSEMBLY - SINGLE REAR WHEEL
1. Install lower differential side gear (1) and shim (Fig. 42).
2. Install first differential pinions gears (1) with spherical washers and mate shaft (2) (Fig. 43).
3. Install second pinion gears (2) with spherical washers and mate shaft (1) (Fig. 44).
4. Install upper differential side gear (1) and shim (2) (Fig. 45).
5. Install differential cover with location numbers (1) on differential case (2) aligned (Fig. 46).
6. Install differential cover (2) bolts (1) and tighten to 45 Nm (33 ft. lbs.) (Fig. 47).
7. Check torque to rotate the differential gears with Torque Tool 9744 and a torque wrench. Torque should be 20-40 Nm (15-30 ft. lbs.).
NOTE: Shims are available in 0.05 mm (0.002 in.) increments, in thicknesses from 1.30 - 2.00 mm (0.051 - 0.078 in.).
ASSEMBLY - DUAL REAR WHEEL
1. Install lower differential side gear (1) and shim (Fig. 48).
2. Install first differential pinions gears (2) with spherical washers (3) and cross shaft (1) (Fig. 49).
3. Install upper differential side gear (1) and shim (2) (Fig. 50).
4. Install differential cover with location numbers (1) on differential case (2) aligned (Fig. 51).
5. Install differential cover (2) bolts (1) and tighen to 45 Nm (33 ft. lbs.) (Fig. 52).
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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