Dodge Ram Truck 1500-2500-3500. Manual — part 1868

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).

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

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

mainshaft (1).

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.).

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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.

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

mode sleeve.

11. Install the mode fork (2), sleeve (3), and shift rail

(1) into the transfer case.

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

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

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13. Install the transfer case position sensor or switch

(2). Tighten the sensor or switch to 20-34 N·m
(15-25 ft. lbs.) torque.

14. Install manual shift lever (3)and spacer onto sec-

tor shaft (1).

15. 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.

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

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