2002 DODGE RAM Service Repair Manual

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Page 1889 of 2255

DODGE RAM 2002 Service Repair Manual (7) Remove rear case and oil pump assembly from front case. (8) Remove shift rail cup and spring (Fig. 14). (9) Remove front sprocket retaining ring (Fig. 15). (10) Pull mainshaft, front sprocket and

Page 1890 of 2255

DODGE RAM 2002 Service Repair Manual (3) Remove poppet plunger screw and spring (Fig. 19). Note that screw has O-ring seal. Remove and discard seal this seal. (4) Remove poppet plunger with magnet (Fig. 20). (5) Remove front output shaft

Page 1891 of 2255

DODGE RAM 2002 Service Repair Manual (7) Remove mode fork, sliding clutch and shift rail as assembly (Fig. 23). Note which way clutch fits in fork (long side of clutch goes to front). (8) Remove range fork retaining ring. (9) Remove rang

Page 1892 of 2255

DODGE RAM 2002 Service Repair Manual MAINSHAFT (1) Remove retaining ring that secures synchro- nizer hub onto mainshaft (Fig. 27). Use standard (instead of parallel jaw) snap-ring pliers to remove this retaining ring. (2) Remove synchron

Page 1893 of 2255

DODGE RAM 2002 Service Repair Manual (5) Remove drive sprocket (Fig. 31). INPUT AND PLANETARY GEAR (1) Remove front bearing retainer attaching bolts (Fig. 32). (2) Remove front bearing retainer. Pry retainer loose with pry tool positione

Page 1894 of 2255

DODGE RAM 2002 Service Repair Manual (5) Place front case in horizontal position. Then remove input gear and low range gear as an assem- bly (Fig. 35). Tap gear out of bearing with plastic mallet, if necessary. INPUT AND PLANETARY GEAR (

Page 1895 of 2255

DODGE RAM 2002 Service Repair Manual INSPECTION MAINSHAFT/SPROCKET/HUB Inspect the splines on the hub and shaft and the teeth on the sprocket (Fig. 41). Minor nicks and scratches can be smoothed with an oilstone, however, replace any par

Page 1896 of 2255

DODGE RAM 2002 Service Repair Manual Fig. 41 Mainshaft Components 1 - DRIVE SPROCKET 5 - STRUTS 2 - STOP RING 6 - SYNCHRO SPRINGS 3 - SYNCHRO HUB 7 - MAINSHAFT 4 - RETAINING RING Fig. 42 Input Gear And Carrier Components 1 - PLANETARY CA
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