Propeller Shaft: Removal & Installation RAM Pickup 2500

INSTALLATION

1. Install propeller shaft with all reference marks (4) aligned.
2. Install with dust boot clamp at transfer case end.
3. Install new axle companion flange bolts and tighten to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) . NOTE: Companion flange bolts incorporate a Loctite R patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite R 242 to the threads.
4. Install skid plate, if equipped.

Scheme 28

1. With vehicle in neutral, position vehicle on hoist.
2. Remove exhaust crossover pipe.
3. Mark a line across axle (3) transfer case (2) companion flange and propeller shaft flange yokes for installation reference.
4. Remove axle/transfer case companion flange bolts.
5. Remove propeller shaft.

1. Install propeller shaft (1) with all reference marks aligned.
2. Install transfer case companion flange (2) bolts and tighten to specification.
3. Install new axle companion flange (3) bolts and tighten to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) . NOTE: Companion flange bolts incorporate a Loctite R patch, new bolts should be used. If bolts are not available, clean bolts and apply Loctite R 242 to the threads.
4. Install skid plate, if equipped.

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1. With vehicle in neutral, position vehicle on hoist.
2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3).
3. If equipped with a center bearing (1) mark an outline of the center bearing (1) on the center bearing bracket for installation reference. Then support propeller shaft and remove mounting bolts (2).
4. Remove pinion flange (1) bolts from propeller shaft (2).
5. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference.
6. Remove propeller shaft from vehicle.

1. Slide slip yoke (1) onto automatic transmission/transfer case output shaft (2) with reference marks aligned.
2. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) .
3. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) .

Scheme 34

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1. With vehicle in neutral, position vehicle on hoist.
2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3).
3. Mark transmission flange (1) if equipped and propeller shaft flange (2) for installation reference.
4. If equipped with a center bearing (1) mark an outline of the center bearing on the center bearing bracket for installation reference. Then support propeller shaft and remove center bearing bolts (2).
5. Remove pinion flange (1) bolts from propeller shaft (2).
6. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference.
7. If equipped with transmission flange (1) remove bolts (2).
8. Remove propeller shaft from vehicle.

1. Slide slip yoke (1) onto automatic transmission/transfer case output shaft (2) with reference marks aligned.
2. If equipped with manual transmission, align transmission flange (1) and propeller shaft reference marks. Install new flange bolts (2) and tighten to 115 N.m (85 ft. lbs.).
3. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) .
4. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to specification. Refer to «Specifications»(ref-457778-S40469726522012030200000) .

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1. Remove propeller shaft.
2. Mark propeller shaft, link yoke and flange yoke for assembly reference.
3. Tap outside of the bearing cap assembly with drift to loosen snap rings.
4. Remove all bearing cap snap rings.
5. Remove grease fittings if equipped.
6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke.
7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap.
8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws.
9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap.
10. Flip assembly and repeat. Refer to steps 6 , 7 , and 8 . To remove the opposite bearing cap, refer to step 9 .
11. Remove cross centering kit assembly and spring.
12. Press remaining bearing caps out the other end of the link yoke.

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1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores.
2. Fit cross into the propeller shaft yoke.
3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap.
4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring.
5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring.
6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings.
7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned.
8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit.
9. Press remaining two bearing caps into place and install snap rings.
10. Tap snap rings to seat them into the grooves.
11. Flexing the joint beyond center, the joint should snap over-center in both directions if correctly assembled.
12. Install propeller shaft.

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1. Place shaft yoke in vise.
2. Position U-joint press (1) with receiver (2) on propeller shaft yoke.
3. Pressed U-joint bearing caps (1) out of shaft yoke (2).
4. Remove lower bearing cap from shaft yoke.
5. Turn shaft over and position press (1) with receiver (2) on shaft yoke.
6. Press remaining U-joint bearing cap out of shaft yoke.
7. Remove flange (1) with U-joint out of shaft yoke (2).
8. Position U-joint press (2) with receiver (1) on flange.
9. Press U-joint bearing caps (1) out of flange (2).
10. Remove bearing cap on the outside of the flange.
11. Position U-joint press (2) with receiver (1) on flange.
12. Press remaining U-joint bearing cap out of flange.
13. Remove U-joint from flange.

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1. Tap outside of bearing cap with a drift to loosen snap ring.
2. Remove snap rings (1) from both sides of yoke.
3. Position yoke with the grease fitting if equipped, pointing up.
4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press.
5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If bearing cap will not pull out of the yoke after pressing, tap yoke ear near bearing cap to dislodge the cap.
6. Pull bearing cap of the yoke.
7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed.

Scheme 61

Note. Replacement joint has internal snap rings.

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1. Place joint in flange with one bearing cap.
2. Position press (3) with receiver (1) on flange and bearing cap (2).
3. Press bearing cap until snap ring groove (1) is through the flange (2).
4. Install snap ring (2) on bearing (1).
5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange.
6. Press bearing cap until snap ring groove is through the flange.
7. Install snap ring (1) on bearing cap (2).
8. Install flange (1) with U-joint in yoke (2).
9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke.
10. Press bearing cap until snap ring groove is through the yoke.
11. Install snap ring (2) on bearing cap (1).
12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke.
13. Press remaining bearing cap until snap ring groove is through the yoke.
14. Install snap ring (2) on bearing cap (1).

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1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores.
2. Position cross (1) in yoke (2) with lube fitting pointing up, if equipped.
3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore.
4. Press bearing cap into the yoke bore enough to clear snap ring groove.
5. Repeat and refer to step 3 to install the opposite bearing cap. Refer to step 4 . NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings.
6. Add grease to lube fitting, if equipped.
7. Install propeller shaft.