Dodge Ram Truck 1500-2500-3500. Manual — part 1901

8. Install snap-ring (2) to hold input/low range gear (1)

into front bearing.

9. Install a new input gear oil seal with Installer 9036

and Handle C-4171.

SHIFT FORKS AND MAINSHAFT

1. Lubricate mainshaft splines with recommended

transmission fluid.

2. Coat the interior of the drive sprocket hub with

ATF+4 and install the drive sprocket drive hub (2)
onto the mainshaft (1).

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3. Install the mode hub (2) onto the mainshaft (1).

4. Install the mode hub (2) retaining ring (3) onto the

mainshaft (1).

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5. Install the clutch gear (2) onto the output shaft (1).

Verify that the pointed ends of the clutch gear teeth
are pointing to the front of the mainshaft.

6. Lubricate sector shaft with transmission fluid and

install shift sector (1) in case. Position slot in sector
so it will be aligned with shift fork pin when shift
forks are installed.

7. Apply Loctite™ 242, or equivalent, to the threads of

the sector support to replentish the factory applied
patch. Install the shift sector support. Tighten the
sector support with Socket 9033 to 27-34 N·m
(20-25 ft.lbs.).

8. Assemble and install range fork (2) and hub (1). Be

sure hub is properly seated in low range gear and
engaged to the input gear.

9. Align and insert range fork pin in shift sector slot.

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10. Install mode fork and shift rail onto the mode

sleeve.

11. Install the mode fork (2), sleeve (1), and shift rail

(2) into the transfer case.

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

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

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

DR/DH

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