Dodge Durango (DN). Manual — part 149
Fig. 65 Install Low Range Gear Snap Ring
1 – LOW RANGE GEAR SNAP RING
Fig. 66 Input Gear Snap Ring Installation
1 – INPUT GEAR
2 – SNAP RING
Fig. 67 Installing Front Bearing Retainer
1 – FRONT BEARING RETAINER
Fig. 68 Sector O-Ring And Bushing Installation
1 – SECTOR BUSHING
2 – O-RING
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Install new pads on low range fork, if neces-
sary, (Fig. 69).
(4) Assemble low range fork and hub (Fig. 69).
(5) Position low range fork and hub in case. Be
sure low range fork pin is engaged in shift sector slot
(Fig. 70).
(6) Install first mainshaft bearing spacer on main-
shaft (Fig. 71).
(7) Install bearing rollers on mainshaft (Fig. 71).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(8) Install remaining bearing spacer on mainshaft
(Fig. 71). Do not displace any bearings while install-
ing spacer.
(9) Install differential (Fig. 72). Do not displace
mainshaft bearings when installing differential.
(10) Install differential snap-ring (Fig. 73).
(11) Install intermediate clutch shaft (Fig. 74).
(12) Install clutch shaft thrust washer (Fig. 75).
(13) Install clutch shaft snap-ring (Fig. 76).
(14) Inspect mode fork assembly (Fig. 77). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 77). Replace
worn, damaged components.
Fig. 69 Assembling Low Range Fork And Hub
1 – LOW RANGE FORK
2 – PADS
3 – HUB
Fig. 70 Positioning Low Range Fork
1 – SHIFT SECTOR
2 – LOW RANGE FORK
3 – PIN
4 – SLOT
Fig. 71 Installing Mainshaft Bearing Rollers and
Spacers
1 – MAINSHAFT BEARING ROLLERS
2 – BEARING SPACERS
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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 72 Differential Installation
1 – DIFFERENTIAL
2 – MAINSHAFT
Fig. 73 Installing Differential Snap-Ring
1 – DIFFERENTIAL SNAP RING
Fig. 74 Installing Intermediate Clutch Shaft
1 – INTERMEDIATE CLUTCH SHAFT
Fig. 75 Installing Clutch Shaft Thrust Washer
1 – CLUTCH SHAFT THRUST RING
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DISASSEMBLY AND ASSEMBLY (Continued)
(15) Install mode sleeve in mode fork (Fig. 78).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(16) Install mode fork and mainshaft assembly in
case (Fig. 79). Rotate mainshaft slightly to engage
shaft with low range gears.
(17) Rotate mode fork pin into shift sector slot.
(18) Install shift rail (Fig. 80). Be sure rail is
seated in both shift forks.
(19) Rotate shift sector to align lockpin hole in low
range fork with access hole in case.
(20) Insert an easy-out in range fork lockpin to
hold it securely for installation (Fig. 81). Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(21) Insert lockpin through access hole and into
shift fork (Fig. 81). Then remove easy-out and seat
the pin with pin punch.
(22) Install plug in lockpin access hole.
(23) Install detent plunger, detent spring and
detent plug in case (Fig. 82).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install front output shaft (Fig. 83).
(2) Install drive chain (Fig. 83). Engage chain with
front output shaft sprocket teeth.
Fig. 76 Installing Clutch Shaft Snap-Ring
1 – SNAP RING
2 – INTERMEDIATE CLUTCH SHAFT
Fig. 77 Mode Fork Assembly Inspection
1 – SLIDER
2 – MODE FORK
3 – BUSHING/SPRING
4 – TUBE
5 – PADS
Fig. 78 Installing Mode Fork And Sleeve
1 – MAINSHAFT
2 – SLEEVE
3 – MODE FORK ASSEMBLY
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DISASSEMBLY AND ASSEMBLY (Continued)
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