2003 DODGE RAM Service Repair Manual

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Page 2481 of 2895

DODGE RAM 2003 Service Repair Manual SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (Fig.

Page 2482 of 2895

DODGE RAM 2003 Service Repair Manual (6) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 67). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(7) App

Page 2483 of 2895

DODGE RAM 2003 Service Repair Manual (13) Install the transfer case position sensor (Fig.
71). Tighten the sensor to 20-34 N´m (15-25 ft. lbs.)
torque.
(14) Install manual shift lever and spacer onto sec-
tor shaft (Fig. 72).
(15) Insta

Page 2484 of 2895

DODGE RAM 2003 Service Repair Manual FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 75) into the
front output shaft front bearing.
(2) Install the front output shaft bearing inner
snap-ring (Fig. 76) onto the

Page 2485 of 2895

DODGE RAM 2003 Service Repair Manual (9) Install rear sprocket retaining ring (Fig. 79).
(10) Install spring onto shift rail (Fig. 80).
(11) Insert magnet in front case pocket (Fig. 81).
REAR CASE
(1) Install the oil pick-up tube and scr

Page 2486 of 2895

DODGE RAM 2003 Service Repair Manual (6) Install rear output bearing inner snap-ring
(Fig. 84) to output shaft.OIL PUMP AND REAR EXTENSION
(1) Install the oil pump (Fig. 85) onto the output
shaft.
(2) Engage the oil pump pick-up tube (Fi

Page 2487 of 2895

DODGE RAM 2003 Service Repair Manual (3) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess coul

Page 2488 of 2895

DODGE RAM 2003 Service Repair Manual (7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
co

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