Dodge Ram Truck 1500-2500-3500. Manual — part 1880

17. Install new o-ring (1) on detent plug (2).

18. Install detent plunger (4), spring (3), and plug (2).

Tighten the plug to 16-25 N·m (12-18 ft. lbs.).

FRONT OUTPUT SHAFT AND DRIVE CHAIN

1. Install the front output shaft (2) into the front output

shaft bearing.

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2. Install the front output shaft retaining ring (2) onto

the output shaft (1).

3. Install the new front output shaft seal with Installer

MB991168A.

4. Insert front sprocket (1) in drive chain (2).

5. Install drive chain (2) around mainshaft sprocket.

Then position front sprocket over front shaft.

6. Raise mainshaft about 2.54 cm (one inch) and seat

front sprocket on front output shaft.

7. If mainshaft and mode sleeve were unseated dur-

ing chain installation, align and reseat mainshaft in
input gear and hub.

8. Install front sprocket (1) retaining ring (2).

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9. Install spring (2) and cup (1) on shift rail.

10. Insert magnet (1) in front case pocket (2).

OIL PUMP AND REAR CASE

Lubricate the oil pump components with transmission
fluid before installation. Prime the oil pickup tube by
pouring a little oil into the tube before installation.

CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft inner
bearing race and will become mis-aligned if the
bolts are loosened. If the transfer case failure has
generated any debris which may have become
trapped in the oil pump. the rear case and oil
pump assembly MUST be replaced.

1. Install new o-ring in pickup tube inlet of oil pump.

2. Insert oil pickup tube into the oil pump.

3. Apply bead of Mopar

T

Gasket Maker, or equivalent,

to mating surface of front case. Keep sealer bead
width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case
interior.

4. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case (1) and oil pump

assembly onto the front case (2).

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5. Install 4-5 rear case (1)-to front case (2) bolts (3) to

hold rear case in position. Tighten bolts snug but
not to specified torque at this time.

CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.

6. Apply Loctite™ 242 to remainder of rear case-to-

front case bolt threads and install bolts. Tighten
bolts to 20-27 N·m (15-24 ft. lbs.).

7. Install rear output bearing (2) snap-ring (3) to out-

put shaft (1).

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

1. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts

the rear of the output shaft.

2. Install a new seal boot clamp onto the seal boot.

3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.

4. Position the shift motor and mode sensor assembly onto the transfer case.

5. Install the bolts to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-25

N·m (12-18 ft. lbs.).

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