2002 DODGE RAM Service Repair Manual

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Page 89 of 2255

DODGE RAM 2002 Service Repair Manual REMOVAL
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove shift motor housing cover, gasket and
shield from the housing (Fig. 27).
DISASSEM

REMOVAL
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove shift motor housing cover, gasket and
shield from the housing (Fig. 27).
DISASSEMBLY
(1) Remove E-clips from the shift motor housing
and shaft. Remove shift motor and shift fork from
the housing (Fig. 28).
(2) Remove O-ring seal from the shift motor shaft.
(3) Clean and inspect all components. Replaced
any component that is excessively worn or damaged.
ASSEMBLY
(1) Install a new O-ring seal on the shift motor
shaft.
(2) Insert shift motor shaft through the hole in the
housing and shift fork. The shift fork offset should be
toward the differential.
(3) Install E-clips on the shift motor shaft and
housing.
INSTALLATION
(1) Install shift motor housing gasket.
(2) Guide the shift fork onto the shift collar groove,
while install the shift motor housing cover.
(3) Install shift motor housing shield and tighten
the bolts to 11 N´m (96 in. lbs.).(4) Add 148 ml (5 ounces) of API grade GL 5
hypoid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(5) Install indicator switch, electrical connector
and vacuum harness.
SINGLE CARDAN UNIVERSAL
JOINTS
REMOVAL
Single cardan U-joint components are not service-
able. If defective they must be replaced as a unit.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove axle shaft.
(2) Remove the bearing cap retaining snap rings
(Fig. 29).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(3) Locate a socket with an inside diameter is
larger than the bearing cap. Place the socket (receiv-
er) against the yoke and around the perimeter of the
bearing cap to be removed.
(4) Locate a socket with an outside diameter is
smaller than the bearing cap. Place the socket (driv-
er) against the opposite bearing cap.
Fig. 27 SHIFT MOTOR HOUSING
1 - INDICATOR LAMP SWITCH
2 - DISCONNECT HOUSING
3 - VACUUM SHIFT MOTOR
4 - AXLE SHAFT
5 - SEAL
6 - SHIFT COLLAR
7 - SHIFT FORK
8 - BEARING
9 - INTERMEDIATE AXLE SHAFT
Fig. 28 SHIFT MOTOR COMPONENTS
1 - INDICATOR SWITCH
2 - E-CLIP
3 - O-RING
4 - SHIFT MOTOR
5 - SHIFT FORK
6 - VACUUM PORTS
7 - DISCONNECT HOUSING AND GASKET
3 - 34 FRONT AXLE - 248FBIBR/BE
AXLE VACUUM MOTOR (Continued)

Page 90 of 2255

DODGE RAM 2002 Service Repair Manual (5) Position the yoke with the sockets in a vise
(Fig. 30).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bear

(5) Position the yoke with the sockets in a vise
(Fig. 30).
(6) Tighten the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap and remove spider from the propeller
shaft yoke.
INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket in a vise.
(4) Tighten the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain-
ing clips.
(5) Install the bearing cap retaining clips.
(6) Install axle shaft.
PINION SEAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake calipers and rotors
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 31) .
(9) Use suitable pry tool or slide hammer mounted
screw to remove the pinion shaft seal.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
installer (Fig. 32).
(2) Install yoke on the pinion gear with Installer
C-3718 and Holder 6719 (Fig. 33).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining
nut. Damage to collapsible spacer or bearings may
result.
Fig. 29 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 30 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET WRENCH
2 - VISE
3 - SMALL-DIAMETER SOCKET WRENCH
BR/BEFRONT AXLE - 248FBI 3 - 35
SINGLE CARDAN UNIVERSAL JOINTS (Continued)

Page 91 of 2255

DODGE RAM 2002 Service Repair Manual (3) Install a new nut on the pinion gear. Tighten
the nut only enough to remove the shaft end play.
(4) Rotate the pinion shaft using an inch pound
torque wrench. Rotating torque should be equal to
th

Page 92 of 2255

DODGE RAM 2002 Service Repair Manual DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove lubricant fill hole plug from the differ-
ential housing cover.
(3) Remove differential housing cover and drain
the lubricant from the ho

Page 93 of 2255

DODGE RAM 2002 Service Repair Manual (13) Pry the differential case loose from the hous-
ing. To prevent damage, pivot on housing with the
end of the pry bar against spreader (Fig. 38).
(14) Remove the case from housing.
(15) Remove and

Page 94 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are being installed, differential side
bearing shim requirements may change. Refer to
Adjustments (Differential Bearing P

Page 95 of 2255

DODGE RAM 2002 Service Repair Manual (10) Apply a bead of red Mopar Silicone Rubber
Sealant or equivalent to the housing cover (Fig. 44).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new

Page 96 of 2255

DODGE RAM 2002 Service Repair Manual INSTALLATION
(1) Install differential side bearings with Installer
C-4190 and Handle C-4171 (Fig. 46).
(2) Install differential case in axle housing.
PINION GEAR/RING GEAR
REMOVAL
NOTE: The ring and p

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