Dodge Ram Truck 1500-2500-3500. Manual — part 1856

7. Install the drive sprocket (3) thrust washer (2) onto

the output shaft (1).

8. Install the drive sprocket retaining ring (2) onto the

output shaft (1).

9. 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.

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10. Install the shift sector support (1). Tighten the sec-

tor support to 27-42 N·m (20-30 ft.lbs.).

11. 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.

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

13. Install the range fork retaining ring.

14. Install mode fork (1) and shift rail (2) onto the

mode sleeve (3).

15. Install the mode fork, sleeve, and shift rail into the

transfer case.

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16. Install mainshaft (2) into the transfer case (1).

Guide mainshaft through the mode and range
sleeves and into the input gear.

17. Install the transfer case position sensor or switch

(2). Tighten the sensor or switch to 20-34 N·m
(16-25 ft. lbs.) torque.

18. Install range lever (1) on sector shaft.

19. Install washer and nut on sector shaft to secure

shift lever. Apply 1-2 drops Mopar

T

Lock N’ Seal,

or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N·m (20-25 ft. lbs.)
torque.

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

21. 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.

DR/DH

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