Dodge Ram Truck 1500-2500-3500. Manual — part 1859

FRONT OUTPUT SHAFT SEAL

REMOVAL

1. Remove the front propeller shaft (Refer to 3 - DIF-

FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).

2. Remove the front propeller shaft seal boot (1)

retaining clamp (2).

3. Remove the front propeller shaft seal boot (1).

4. Remove the front output shaft seal slinger (1) by

bending (2) the slinger ears away from the transfer
case.

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5. Using a suitable pry tool (2), remove the slinger (1)

from the output shaft using care not to damage the
shaft.

6. Using a screw and a slide hammer, remove the

front output shaft seal.

INSTALLATION

1. Install the new front output shaft seal with Installer MB991168A.

2. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts

the rear of the output shaft.

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

4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.

5. Install front propeller shaft (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER

SHAFT - INSTALLATION).

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LEVER-SHIFT

REMOVAL

1. Shift transfer case into 2H.

2. Raise and support the vehicle.

3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of

trunnion, push trunnion out of shift lever.

4. Lower vehicle.

5. Remove transfer case shifter knob cap.

6. Remove nut holding shifter knob (2) to shift lever.

7. Remove shifter knob.

8. Remove the shift boot from the shifter console.

9. Remove the bolts securing the shifter mechanism to the floor pan.

10. Separate shift lever mechanism from the vehicle.

Transfer Case Shifter

1 - SHIFTER BOOT

4 - SHIFTER MECHANISM

2 - SHIFTER KNOB

5 - ALIGNMENT PIN

3 - SHIFTER CONSOLE

6 - TRANSFER CASE

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INSTALLATION

1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the

shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the
position.

2. Position shift lever in vehicle.

3. Install the bolts to hold the shifter mechanism (4) to the floor pan.

4. Raise vehicle.

5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the

second position from full forward.

6. Install trunnion to shift lever, if necessary.

7. Install shift rod to trunnion, if necessary.

8. Tighten the shift rod lock bolt to 10 N·m (90 in.lbs.).

9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole.

10. Lower vehicle.

11. Install the transfer case shifter console.

12. Install the shifter boot and the shifter knob onto the shifter lever.

13. Install nut to hold shifter knob to shift lever.

14. Install shifter knob cap.

15. Verify transfer case operation.

Transfer Case Shifter

1 - SHIFTER BOOT

4 - SHIFTER MECHANISM

2 - SHIFTER KNOB

5 - ALIGNMENT PIN

3 - SHIFTER CONSOLE

6 - TRANSFER CASE

DR/DH

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