Dodge Ram Truck 1500-2500-3500. Manual — part 1890

6. Install the new front output shaft seal slinger (1)

with Installer 8840 (2). Install the slinger onto the
shaft until the tool contacts the front of the output
shaft.

7. Install the front sprocket (1), rear sprocket (3), and

chain (2) as an assembly.

8. Lower the front sprocket, rear sprocket, and chain

over the front and rear output shafts simultaneously
until fully seated on both splines.

9. Install the rear output shaft retaining ring (2) onto

the output shaft (1).

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10. Install the front sprocket (1) retaining ring (2).

11. Inspect mode fork assembly (1). Replace pads if

necessary. Also check springs and slider bracket.
Replace worn or damaged components.

12. Install the mode fork (2) and sleeve (3) over the

shift rail (1) and mainshaft.

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13. Install spring (2) onto the shift rail (1).

14. 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, if

necessary.

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.

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

assembly (1).

5. Install rear output bearing snap-ring (3) to output

shaft (1).

6. Install 4-5 rear case-to front case bolts (3) to hold

rear case (1) 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.

7. Apply Mopar

T

Lock ’n Seal Adhesive to remainder

of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 N·m (18-21 ft. lbs.),

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

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

2. Install the seal boot (2) and clamp onto the slinger

(2) hub and tighten the clamp with Crimp Tool
C-4975-A.

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