Dodge Ram Truck 1500-2500-3500. Manual — part 1861

REMOVAL

1. Raise and support vehicle.

2. Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE

- REMOVAL)

3. Position drain oil container under transfer case.

4. Remove transfer case drain plug and drain lubricant into container.

5. Disconnect vent hose and transfer case position sensor connector.

6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy

access. Use channel lock style pliers to press rod out of lever grommet.

7. Support transmission with jack stand.

8. Mark front and rear propeller shafts for assembly reference.

9. Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-

PELLER SHAFT - REMOVAL)

10. Support transfer case with suitable jack. Secure transfer case to jack with safety chains.

11. Remove nuts attaching transfer case to transmission.

12. Move transfer case assembly rearward until free of transmission output shaft.

13. Lower jack and move transfer case from under vehicle.

DISASSEMBLY

Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.

COMPANION FLANGE AND EXTENSION HOUSING

1. Install two bolts 180° apart into the front output

shaft companion flange.

2. Place holder (1) over the bolts (2) and against the

companion flange.

3. Remove and discard the front companion flange

nut.

4. Remove the companion flange from the front out-

put shaft. It may be necessary to use Flange puller
8992 to remove the companion flange.

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5. Use a suitable chisel or pry tool to remove the rear

extension housing (1) dust boot (2).

6. Use a suitable chisel or pry tool to remove the rear

extension housing seal.

7. Remove rear extension (1) bolts (2).

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8. Remove rear extension housing (2) from the rear

case half. Tap extension once or twice with a plas-
tic mallet to break sealer bead and loosen it.

OIL PUMP AND REAR CASE

1. Disengage the oil pump pick-up tube (2) from the

oil pump (1).

NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.

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2. Remove the oil pump (3) from the rear output shaft

(2).

3. Remove rear case (2)-to-front case (1) bolts (3).

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