Ram Truck 1500, 2500 & 3500 (2006-2008)

Intermediate Shaft & Seal

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Removal & Installation



C205FD
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove half shaft from disconnect side of the axle.
  4.  
  5. Remove disconnect actuator wiring connector.
  6.  
  7. Remove disconnect actuator bolts and remove actuator.
  8.  
  9. Remove O-ring and snap ring from output shaft.
  10.  
  11. Remove disconnect seal bolts.
  12.  
  13. Remove output shaft and disconnect seal with Remover 8420A (3) and Slide Hammer C-3752.

    Click image to see an enlarged view

    Fig. output shaft (1), seal (2) tool 8420A (3)

  14.  
  15. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket.

    Click image to see an enlarged view

    Fig. Disconnect collar (1), intermediate shaft (2)

  16.  
  17. Remove differential cover.
  18.  
  19. Drive intermediate shaft out of side gear with a hammer and brass punch.

    Click image to see an enlarged view

    Fig. Intermediate shaft removal with a hammer and brass punch

  20.  
  21. Remove intermediate shaft from axle tube.
  22.  

To install:

  1. Install new intermediate shaft snap ring.
  2.  
  3. Install shaft into axle tube and side gear. Verify intermediate shaft snap ring is seated in side gear.
  4.  
  5. Install disconnect collar through disconnect pocket onto intermediate shaft.
  6.  
  7. Position disconnect collar on intermediate shaft, so collar is in 2WD position.
  8.  
  9. Verify output shaft bearing cup is seated in the disconnect pocket.
  10.  
  11. Install output shaft with bearing into disconnect pocket.
  12.  
  13. Install disconnect seal on output shaft.
  14.  
  15. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins MD998412 (2).
  16.  
  17. Install disconnect seal (1) in disconnect pocket with Installer 6761 (2) and a hammer.

    Click image to see an enlarged view

    Fig. Disconnect seal installation shown

  18.  
  19. Install disconnect seal bolts and tighten to 21 ft. lbs. (28 Nm).
  20.  
  21. Install output shaft O-ring and snap ring.
  22.  
  23. Clean actuator sealing surface and install new gasket if necessary.
  24.  
  25. Align actuator shift fork with disconnect collar and install actuator on disconnect pocket.
  26.  
  27. Install disconnect actuator bolts and tighten to 20 ft. lbs. (27 Nm).
  28.  
  29. Install disconnect actuator wiring connector.
  30.  
  31. Install differential cover and fill differential to specification.
  32.  
  33. Install half shaft.
  34.  

 
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