Dodge Ram Truck 1500-2500-3500. Manual — part 1851

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

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

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

front output shaft seal.

REAR EXTENSION

1. Remove rear extension (1) bolts.

2. Remove rear extension housing (1). Tap extension

once or twice with a plastic mallet to break sealer
bead and loosen it.

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3. Remove output bearing (2) retaining ring (3) with

heavy duty snap-ring pliers.

OIL PUMP AND REAR CASE

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

2. Loosen rear case (1) with pry tool to break sealer

bead. Insert tool in slot (3) at each end of case.

DR/DH

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3. Unseat rear case (1) from alignment dowels.

4. Remove rear case and oil pump assembly from

front case.

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 bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gen-
erated

any

debris

which

may

have

become

trapped in the oil pump, the rear case and oil
pump assembly MUST be replaced.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

1. Remove shift rail (1) cup (3) and spring (2).

2. Remove front sprocket (1) retaining ring (2).

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3. Pull mainshaft (3), front sprocket (1) and chain out-

ward about 25.4 mm (1-inch) simultaneously.

4. Remove chain from mainshaft drive sprocket and

remove front sprocket and chain as assembly.

SHIFT FORKS AND MAINSHAFT

1. Remove the transfer case position switch (2).

2. Loosen detent plug (2).

3. Remove detent plug (2), spring (3), and plunger

(4). Note that the plug has an O-ring seal. Remove
and discard this seal.

DR/DH

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