2003 DODGE RAM Service Repair Manual

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Page 2545 of 2895

DODGE RAM 2003 Service Repair Manual (7) Install snap-ring to hold input/low range gear into front bearing (Fig. 61). (8) Install a new input gear seal using Installer 8841 and Handle C-4171. (9) Install a new input gear oil seal with In

Page 2546 of 2895

DODGE RAM 2003 Service Repair Manual (5) Install the clutch gear (Fig. 65) onto the output shaft. Verify that the pointed ends of the clutch gear teeth are pointing to the front of the mainshaft. (6) Lubricate sector shaft with transmiss

Page 2547 of 2895

DODGE RAM 2003 Service Repair Manual (12) Install new o-ring on detent plug (Fig. 69). (13) Install detent plunger, spring, and plug (Fig. 70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.). (1) Position the shift motor and mode sensor

Page 2548 of 2895

DODGE RAM 2003 Service Repair Manual (3) Install mainshaft into the transfer case (Fig. 73). Guide mainshaft through the mode and range sleeves and into the input gear. FRONT OUTPUT SHAFT AND DRIVE CHAIN (1) Install the front output shaf

Page 2549 of 2895

DODGE RAM 2003 Service Repair Manual (8) Install front sprocket retaining ring (Fig. 77). (9) Install rear sprocket retaining ring (Fig. 78). (10) Insert magnet in front case pocket (Fig. 79). REAR CASE (1) Install the oil pick-up tube a

Page 2550 of 2895

DODGE RAM 2003 Service Repair Manual (4) Install 4-5 rear case-to front case bolts (Fig. 81) to hold rear case in position. Tighten bolts snug but not to specified torque at this time. CAUTION: Verify that shift rail, and case alignment

Page 2551 of 2895

DODGE RAM 2003 Service Repair Manual (2) Engage the oil pump pick-up tube (Fig. 84) into the oil pump. Verify that the pick-up tube o-ring is on the tube and is correctly installed to the oil pump. (3) Apply bead of MopartGasket Maker, o

Page 2552 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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