Bee,

Having rebuilt a few 9.25 Mopar rears, including machining custom axle
shafts, installing limited slips, and such, the screwdriver method works
fine. As a matter of fact thats why the factory places the adjustment holes
in the side adjusters.  It's not practical to buy every tool the service
manual recommends. The only tools you really need are a dial indicator and a
good mechanical sense.

Tony

This is why the manual tells you to take it somewhere to get it done.  Phillip
screwdrivers don't make good torque wrenches.

beekeep

After you clean everything out and check for damage, you re-install the ring
gear/carrier. You'll need a dial indicator with a magnetic base or some
fixture to hold the indicator against one of the teeth on the ring gear, and
rock the gear. Tighten the side adjusters until you get around .007"
backlash. I use a phillips screwdriver, placed in the adjustment hole of the
casting and pry against one of the holes in the side adjuster, tightening
until snug.

Then replace your adjuster locks.

Tony

Really hard to say just looking at the pictures but it looks like the drivers
side adjuster keeper is broken off.  The gears don't look bad but the backlash
should be checked and some prussen sp? blue used to verify the contact area.
You're going to need a special tool for setting the torque on the adjusters.
You have to do it with the axles removed.  The tool is simple enough to make.  A
nut welded on one end of 2' of 1/2" all thread and a hexhead pipe bushing welded
on the other end.  The right size hexhead has to be selected to fit into the
adjuster.  You might as well replace the wheel bearings and seals while you have
it apart.  Don't forget to check the backlash every time you change the
adjusters and after you torque every thing down.  Make up a jig to hold the dial
indicator that bolts to the case using one of the cover bolt holes.

beekeep

I decided to take pictures as I go along. See

http://igor.chudov.com/projects/Automotive/Drivetrain-Noise-In-Dodge-RAM-1500-Pickup/

Some findings as I opened up the differential.

1. It is full of gear oil. (means my oil change 2 years ago was successful)

2. On the bottom there is some amount of of, like, 100 grit metal
dust, settled down.

3. There was one foreign object on the bottom, see

  http://tinyurl.com/zr8zg

4. The gears and such, do not seem to have any unusual damage.

i