Ram B1500, B2500, B3500, 1999-2003

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Shift the transfer case into N .
  4.  
  5. Remove or disconnect the following:

    Front and rear driveshafts
     
    Transmission mount and crossmember. Support the transmission.
     
    Vehicle Speed (VSS) sensor connector
     
    Shift linkage
     
    Vent hose
     
    Vacuum hose
     
    Indicator switch connector
     
    Transfer case attaching nuts
     
    Transfer case

    Click image to see an enlarged view

    Fig. Typical transfer case mounting

     

  6.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the nuts to 26 ft. lbs. (35 Nm).
     
    Indicator switch connector
     
    Vacuum hose
     
    Vent hose
     
    Shift linkage
     
    VSS sensor connector
     
    Transmission mount and crossmember
     
    Front and rear driveshafts
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Shift the transfer case into N .
  4.  
  5. Remove or disconnect the following:

    Front and rear driveshafts
     
    Transmission mount and crossmember. Support the transmission.
     
    Vehicle Speed (VSS) sensor connector
     
    Shift linkage
     
    Vent hose
     
    Vacuum hose
     
    Indicator switch connector
     
    Transfer case attaching nuts
     
    Transfer case
     

  6.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the nuts to 26 ft. lbs. (35 Nm).
     
    Indicator switch connector
     
    Vacuum hose
     
    Vent hose
     
    Shift linkage
     
    VSS sensor connector
     
    Transmission mount and crossmember
     
    Front and rear driveshafts

    Click image to see an enlarged view

    Fig. Typical transfer case mounting

     

  2.  

  1. Disconnect the battery negative cable.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. Drain the transfer case lubricant.
  6.  
  7. Matchmark the front and rear drive shafts on yokes or flanges so that they can be reinstalled in the original positions.
  8.  
  9. Remove the skidplate, if fitted, and rear frame crossmember if needed for clearance.
  10.  
  11. Disconnect both driveshafts from the transfer case.
  12.  
  13. Disconnect the PTO, if fitted.
  14.  
  15. Disconnect the shift linkage.
  16.  
  17. Disconnect the vent hose and any switch connectors fitted to the case.
  18.  
  19. Disconnect the wires of the vehicle speed sensor, if fitted.
  20.  
  21. Support the case with a transmission jack. Secure the transfer case to the jack with chains.
  22.  
  23. Remove the nuts securing the transfer case to the transmission.
  24.  
  25. Pull the assembly back towards the rear of the vehicle to disengage it.
  26.  
  27. Remove the transfer case from the vehicle.
  28.  

To install:

  1. Reverse the removal procedure.
  2.  
  3. Tighten the transfer case-to-transmission nuts. Tighten 5 / 16 in. nuts to 22-30 ft. lbs. Tighten 3 / 8 in. nuts to 30 -35 ft. lbs. (41-47 Nm).
  4.  
  5. Be sure to add the proper amount and grade of fluid.
  6.  



Click image to see an enlarged view

Fig. Transfer case driveline-typical



Click image to see an enlarged view

Fig. Transfer case mounting arrangement-typical



Click image to see an enlarged view

Fig. Transfer case shift assembly-typical

 
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