Front Axle - C205FD: Removal & Installation RAM Pickup 2500

INSTALLATION

1. Raise axle into position.
2. Install engine mount bolts and tighten to specifications. Refer to «Specifications»(ref-457782-S40521285042012030200000) .
3. Install axle shaft tube (1) mounting bolts (2). Tighten bolts (2) to specifications. Refer to «Specifications»(ref-457782-S40521285042012030200000) .
4. Install axle housing pinion nose mounting bolts (1) and tighten to specifications. Refer to «Specifications»(ref-457782-S40521285042012030200000) .
5. Install vent hose (1) on differential cover tube (2).
6. Install disconnect actuator (1) wiring connector (2).
7. Install suspension crossmember (1), bolts and nuts (2).
8. Install skid plate (1) and bolts (2).
9. Install front propeller shaft (2) with reference marks (4) aligned. Refer to «SHAFT, Drive, Front Light Duty , Installation»(ref-457778-S21596541902012030200000) or «SHAFT, Drive, Front Heavy Duty , Installation»(ref-457778-S09275572762012030200000) .
10. Install axle half shafts. Refer to «Installation»(ref-457779-S37083729822012030200000) .

REMOVAL

1. Remove half shaft from vehicle.
2. Clean axle seal area.
3. Remove O-ring (1) and snap ring (2) from axle shaft (3).
4. Remove axle with Remove (special tool #8420B, Remover, Shaft) (2,3,4) and Slide Hammer (special tool #C-3752, Slide Hammers).
5. Remove axle shaft seal with a seal puller.

Scheme 207

1. Wipe axle shaft tube bore clean.
2. Install new axle shaft seal with Installer (special tool #8694, Installer, Seal) (1).
3. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear.
4. Install o-ring (1) and snap ring (2) on axle shaft (3).
5. Install half shaft.
6. Verify differential fluid level and add fluid if necessary.

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1. With axle in 2WD remove front propeller shaft and left half shaft.
2. Rotate pinion gear three or four times and verify pinion rotates smoothly.
3. Record pinion torque to rotate with an inch pound torque wrench (2), for installation reference.
4. Position Holder (special tool #6719A, Holder, Yoke) against the companion flange (1) and install a four bolts and washers into the threaded holes and tighten the bolts.
5. Remove pinion nut.
6. Mark a line across the pinion shaft and flange for installation reference.
7. Remove companion flange with (1) Remover (special tool #C-452, Puller, Companion Flange) (2).
8. Remove pinion seal with a seal puller.

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1. Apply a light coating of gear lubricant on the lip of pinion seal.
2. Install seal with Installer (special tool #8695, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
3. Install flange on the pinion shaft with the reference marks aligned.
4. Install companion flange onto the pinion with Installer (special tool #C-3718, Installer, Flange) and Holder (special tool #6719A, Holder, Yoke).
5. Position holder (2) against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange.
6. Install a new pinion nut onto the pinion shaft and tighten the pinion nut until there is zero bearing end-play CAUTION: Do not exceed 271 N.m (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. Failure to follow these instruction will damage the axle.
7. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to recorded reading plus an additional 0.56 N.m (5 in. lbs.).
8. If rotating torque is low, tighten the pinion nut in 6.8 N.m (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. CAUTION: If maximum tightening torque 475 N.m (350 ft. lbs.) is reached prior to reaching the required rotating torque, the collapsible spacer may have been damaged. Failure to follow these instruction will damage the axle.
9. Install propeller shaft and half shafts.

1. Remove half shaft from vehicle.
2. Clean axle seal area.
3. Remove O-ring (1) and snap ring (2) from axle shaft (3).
4. Remove axle with Remove (special tool #8420B, Remover, Shaft) (2,3,4) and Slide Hammer (special tool #C-3752, Slide Hammers).

1. Lubricate bearing bore and seal lip with gear lubricant.
2. Install axle shaft with new snap ring and verify axle shaft snap ring is seated in side gear.
3. Install o-ring (1) and snap ring (2) on axle shaft (3).
4. Install half shaft.
5. Verify differential fluid level and add fluid if necessary.

Scheme 213

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Scheme 215

1. Remove half shaft from disconnect side of the axle.
2. Remove disconnect actuator wiring connector.
3. Remove disconnect actuator (1) bolts (2) and remove actuator.
4. Remove O-ring (1) and snap ring (2) from output shaft.
5. Remove disconnect seal (1) bolts (2).
6. Remove output shaft (1) and disconnect seal (2) with Remover (special tool #8420B, Remover, Shaft) (3) and Slide Hammer (special tool #C-3752, Slide Hammers).
7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket.
8. Remove differential cover.
9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2).
10. Remove intermediate shaft (1) from axle tube (2).

Scheme 216

1. Secure intermediate shaft in vise.
2. Remove output shaft bearing from intermediate shaft (2), with Puller (special tool #9585, Remover, Bearing Cup) (1) and Slide Hammer (special tool #C-637, Slide Hammer, Universal).

Scheme 217

1. Install output shaft bearing (1) in intermediate shaft (3) with Installer (special tool #9768, Remover, Bearing) (2) and Handle (special tool #C-4171, Driver Handle, Universal).

Scheme 218

1. Install new intermediate shaft snap ring.
2. Install shaft (1) into axle tube (2) and side gear. Verify intermediate shaft snap ring is seated in side gear.
3. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2).
4. Position disconnect collar (1) on intermediate shaft (2), so collar is in 2WD position.
5. Verify output shaft bearing cup (1) is seated in the disconnect pocket (2).
6. Install output shaft (1) with bearing into disconnect pocket (2).
7. Install disconnect seal (1) on output shaft (2).
8. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins (special tool #MD998412, Pins, Guide) (2).
9. Install disconnect seal (1) in disconnect pocket with Installer (special tool #6761, Installer, Ball Joint) (2) and a hammer.
10. Install disconnect seal (1) bolts (2) and tighten to 28 N.m (21 ft. lbs.).
11. Install output shaft O-ring (1) and snap ring (2).
12. Clean actuator (1) sealing surface and install new gasket (2) if necessary.
13. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket.
14. Install disconnect actuator (1) bolts (2) and tighten to 27 N.m (20 ft. lbs.).
15. Install disconnect actuator wiring connector.
16. Install differential cover and fill differential to specification.
17. Install half shaft.

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Scheme 226

1. Remove half shaft from disconnect side of the axle.
2. Remove disconnect actuator wiring connector.
3. Remove disconnect actuator (1) bolts (2) and remove actuator from disconnect pocket.
4. Remove O-ring (1) and snap ring (2) from output shaft.
5. Remove disconnect seal (1) bolts (2).
6. Remove output shaft (1) and disconnect seal (2) with Remover (special tool #8420B, Remover, Shaft) (3) and Slide Hammer (special tool #C-3752, Slide Hammers).
7. Slide disconnect collar (1) from intermediate shaft (2) and remove through disconnect pocket.
8. Remove differential cover.
9. Drive intermediate shaft (1) out of side gear with a hammer and brass punch (2).
10. Remove intermediate shaft (1) from disconnect pocket (2).
11. Install Puller (special tool #9766, Remover, Bearing) (1) in intermediate shaft bearing (2) then tighten nut (3) to expand tool in bearing.
12. Tighten puller (1) nut (2) to remove intermediate shaft bearing from disconnect pocket.

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Scheme 232

1. Install intermediate shaft bearing (1) with Installer (special tool #9767, Installer, Bearing) (2) and Handle (special tool #C-4171, Driver Handle, Universal). CAUTION: Bearing must be installed with lettering facing outwards. Failure to follow these instructions will damage the bearing.
2. Install new intermediate shaft snap ring.
3. Install intermediate shaft (1) through disconnect pocket (2) and verify intermediate shaft snap ring is seated in side gear.
4. Install disconnect collar (1) through disconnect pocket onto intermediate shaft (2).
5. Position disconnect collar (1) on intermediate shaft (2) in 2WD position.
6. Verify output shaft bearing cup (1) is seated in disconnect pocket (2).
7. Install output shaft (1) in disconnect pocket (2).
8. Install disconnect seal (1) on output shaft (2).
9. Align disconnect seal (1) with bolt holes in disconnect pocket with Pins (special tool #MD998412, Pins, Guide) (2).
10. Install disconnect seal (1) in disconnect pocket with Installer (special tool #6761, Installer, Ball Joint) (2) and a hammer.
11. Install disconnect seal (1) bolts (2) and tighten to 28 N.m (21 ft. lbs.).
12. Install output shaft O-ring (1) and snap ring (2).
13. Clean actuator (1) sealing surface and install new gasket (2) if necessary.
14. Align actuator shift fork (1) with disconnect collar (2) and install actuator on disconnect pocket.
15. Install disconnect actuator (1) bolts (2) and tighten to 27 N.m (20 ft. lbs.).
16. Install disconnect actuator wiring connector.
17. Install differential cover and fill differential to specification.
18. Install half shaft.