Chrysler RAM TRUCK 2500 1994 Service Manual page 87

2 - 30 FRONT SUSPENSION AND AXLE
SHIFT M O T O R — REMOVAL/DISASSEMBLY
(1) Disconnect the vacuum and wiring connector
from the shift housing.
(2) Remove indicator switch.
(3) Remove the shift motor housing cover, gasket
and shield from the housing (Fig. 10).
INDICATOR LAMP
SWITCH
INTERMEDIATE
AXLE SHAFT
DISCONNECT
HOUSING
VACUUM
SHIFT
MOTOR
BEARING
SHIFT FORK
SHIFT
COLLAR
SEAL
J9402-63
Fig. 10 Shift Motor Housing
(4) Remove the E-clips from the shift motor hous­
ing and shaft. Remove shift motor and shift fork from
the housing (Fig. 11).
INDICATOR
SWITCH
DISCONNECT HOUSING
A N D GASKET
V A C U U M
PORTS
J9202-54
Fig. 11 Shift Motor Components
(5) Remove the O-ring seal from the shift motor shaft.
(6) Clean and inspect all components. I f any com­
ponent is excessively worn or damaged, i t should be
replaced.
ASSEMBLY/INSTALLATION
(1) Install a new O-ring seal on the shift motor shaft.
(2) Insert the shift motor shaft through the hole i n
the housing and shift fork. The shift fork offset
should be toward the differential.
(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover. Ensure the shift f o r k is correctly guided
i n t o the shift collar groove.
(5) Install the shift motor housing shield and attach­
ing bolts. Tighten the bolts to 11 N-m (96 in. lbs.)
torque.
(6) Add 148 ml (5 ounces) of API grade GL 5 hy-
poid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
(7) Install indicator switch, electrical connector
and vacuum harness.
INTERMEDIATE AXLE SHAFT—REMOVAL/
DISASSEMBLY
Service to the Disconnect axle seals and bearing re­
quire the use of Tool Set 6288 (J34659) and Seal In­
staller 6228.
(1) Remove the vacuum motor housing. Refer to
Shift Motor Removal i n this section.
(3) Remove the outer axle shaft. Refer to Hub
Bearing and Axle Shaft in this section.
(4) Remove shift collar and intermediate axle shaft.
(5) Remove the inner axle shaft seal from the shift
motor housing with a long drift or punch. Be careful
not to damage housing.
(6) Remove the intermediate axle shaft bearing
(Fig. 12).
SHIFT MOTOR
H O U S I N G O P E N I N G
AXLE
TUIE
LOCATION
FOR OPEN-END
WRENCH
SPECIAL TOOL
5041-2
SPECIAL TOOL
NUT
J9402-18
Fig. 12 Bearing Removal Tool Installed
ASSEMBLY/INSTALLATION
(1) Position the bearing on installation tool. Seat
the bearing i n the housing bore (Fig. 13).
(2) Clean the inside perimeter of the axle shaft
tube with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(4) Install the inner axle seal (Fig. 14) 44 axle (Fig.
15) 60 axle.
The inner axle seal position is different on a 44
then a 60 axle. Be sure to use the correct installer,
i f wrong installer is use axle w i l l not seal.