Ram 2500 Front Axle Installation

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BD - 27 Jul 2005 02:37 GMT

I have a '96 Dodge Ram 2500 4X4 with an axle lying in my driveway.

I removed the axle on the passenger side to install new U-Joints, this all
went surprisingly well. My problem is that I can't slide the axle back in
the way it came out. It will go in to within an inch and a half or so, but
there is something solid stopping it from going any further. I can feel the
axle (it's 2 pieces by the way) go into what I think are the seals, then
maybe an eighth of an inch more, but that's it. I thought maybe the spline
was just not lining up correctly, but after roughly 478 attempts, I figured
the odds would be in my favor of accidentally aligning them.

I don't want to beat on the axle because I don't want to damage the internal
spline or the seals. What can I try?

Truck is a 1996 2500 4X4 with the heavy duty front end, gas powered V8. The
axle slid out easily, and I marked the top of the axle and the relationship
between the axle halves in the hopes that if done in reverse life would be
good.

TIA
Jim

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Tom Lawrence - 27 Jul 2005 03:57 GMT

They usually just slide right in. Are you sure the U-joint section isn't
getting hung up on the steering knuckle somewhere? Another dumb question -
when it gets hung up, did you turn it back and forth while pushing on it a
little bit?

Remove the CAD motor (four bolts), and you can see the axle as you slide it
in. Maybe the locking collar is gumming up the works. Whatever's causing
the problem (if it's on the spline end), you'll be able to see what's
happening with the CAD removed. When putting the CAD back, make sure the
shift fork properly engages the collar.

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BD - 27 Jul 2005 06:53 GMT

"Tom Lawrence" wrote in message

> They usually just slide right in. Are you sure the U-joint section isn't
> getting hung up on the steering knuckle somewhere? ......

Yes, it's all clear.

> when it gets hung up, did you turn it back and forth while pushing on it a
> little bit?

Yes, but I'm not sure that the inner section was necessarily turning. The
axle is actually two pieces split at the second spline. I could be turning
the outer section, but the inner section could remain stationary. I tried
pulling it out of the seal all the way, rotating it slightly, then trying
again, but I get that same solid feeling stop.

> Remove the CAD motor (four bolts), and you can see the axle as you slide it
> in. Maybe the locking collar is gumming up the works. Whatever's causing
> the problem (if it's on the spline end), you'll be able to see what's
> happening with the CAD removed. When putting the CAD back, make sure the
> shift fork properly engages the collar.

I will try this in the morning if the weather permits, my truck is outside.

As I read this a question comes to mind. If the shift fork must be engaged
when I reinstall the motor, how does it engage by merely sliding the two
piece axle back in the tube?

Thank you for taking the time to respond and offering your help. I am
without a vehicle until I get this taken care of.

Regards,
Jim

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SnoMan - 28 Jul 2005 03:35 GMT

>They usually just slide right in. Are you sure the U-joint section
>isn’t getting hung up on the steering knuckle somewhere?
>Another dumb question -when it gets hung up, did you turn it back and
>forth while pushing on it a little bit?

This is easy, been there and done that years ago. The problem is that
the splined end on the axle shaft is resting in the axle tube and not
lining up with the inner seal opening and allowing it to past through
it to engage the splines in diff. All you need to do here is with axle
resting in the tube after it has been inserted as far as possible with
gentle pressure, is to place a downward force on the shaft still
sticking out (and a little trial and error here) to "lever" the
splined end of shaft off on the bottom of tube and into alignement
with the inner seal bore and and allow the shaft to past through it
and engage the diff splines. It is pretty easy once you get the feel
for it.

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BD - 28 Jul 2005 21:45 GMT

That Did It!!!

Thank you!!

"SnoMan" <UseLinkToEmail@AutoForumz.com> wrote in message

> This is easy, been there and done that years ago. The problem is that
> the splined end on the axle shaft is resting in the axle tube and not
[quoted text clipped - 7 lines]
> and engage the diff splines. It is pretty easy once you get the feel
> for it.

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SnoMan - 29 Jul 2005 00:36 GMT

>That Did It!!!
>
>Thank you!!

You are more than welcome, I discovered that "trick" about 30 years
ago on my own but I have not had to use it for a while.

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