Driveshaft - Front

This procedure covers the removal and installation of the front driveshaft on a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine, including disconnection from the transfer case and front differential.

Warnings

Tools required

Parts

• Driveshaft flange bolts × 8 — Use OEM specification if torque-to-yield
• Transfer case output seal × 1 — Use OEM specification if damaged

Fluids

• ATF+4 — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Raise front of vehicle to working height using floor jack
4. Support vehicle on jack stands placed under frame rails behind front axle
5. Allow exhaust system to cool completely if vehicle was recently driven
6. Position drain pan under transfer case to catch fluid spillage

Procedure

1. 1

   Mark driveshaft orientation
   Using a white paint marker or chalk, make alignment marks on the front driveshaft flange and the front differential companion flange. Also mark the transfer case end of the driveshaft and the transfer case output yoke. These marks ensure proper phasing during reinstallation to prevent vibration.
2. 2

   Remove front driveshaft-to-differential bolts
   Using a pry bar or large screwdriver to prevent rotation of the driveshaft, remove the flange bolts connecting the front driveshaft to the front differential companion flange, verifying the correct socket size and bolt count against the factory service manual. Keep bolts organized as they may be reused if not torque-to-yield. Support the driveshaft center section to prevent it from dropping.
3. 3

   Remove center support bearing bracket
   The front driveshaft on this vehicle is a one-piece shaft and does not use a center support bearing bracket. Skip this step; proceed directly to disconnecting the driveshaft from the transfer case.
   Torque spec

   Center Support Bearing Bracket Bolts50 Nm (37 lb-ft)
4. 4

   Remove driveshaft-to-transfer case bolts
   Using a pry bar to hold the transfer case front output yoke stationary, remove the four bolts connecting the front driveshaft flange to the transfer case front output yoke using a 15mm socket. Minimal fluid loss is expected since the front output shaft seal retains transfer case fluid; position a drain pan as a precaution.
5. 5

   Remove front driveshaft assembly
   Carefully lower and remove the complete front driveshaft assembly from the vehicle. The front driveshaft is a one-piece shaft with a CV/double-cardan joint at one end and a U-joint at the other. Maneuver the assembly past the exhaust and frame components. Place the driveshaft on a clean work surface and avoid placing excessive loads on the CV joint or U-joints.
6. 6

   Inspect components
   Inspect the CV joint boots, U-joint boots, and center support bearing for wear, tears, or grease leakage. Check the transfer case output seal for damage or leakage. Rotate the U-joints and CV joint by hand to check for roughness, binding, or excessive play. Inspect all flanges for cracks or wear. Replace components as necessary before reinstallation.
7. 7

   Clean mating surfaces
   Use a wire brush to clean the mounting surfaces on the front differential companion flange and transfer case output yoke. Remove any rust, corrosion, or old thread locker from the bolt holes. Ensure all surfaces are clean and dry before reinstallation.
8. 8

   Position driveshaft assembly
   With an assistant or using a transmission jack, carefully position the front driveshaft assembly into place. Align the rear flange with the transfer case output yoke first, ensuring the alignment marks made during disassembly are aligned. Install bolts finger-tight but do not torque yet.
9. 9

   Install center support bearing bracket
   This step does not apply — the front driveshaft is a one-piece shaft with no center support bearing bracket. Omit and proceed to connecting the flanges.
   Torque spec

   Center Support Bearing Bracket Bolts50 Nm (37 lb-ft)
10. 10

    Align and connect front flange
    Align the front driveshaft flange with the front differential companion flange, matching the alignment marks. Install the four flange bolts finger-tight. Ensure the CV joint is not twisted or at an extreme angle.
11. 11

    Torque transfer case flange bolts
    Using a pry bar to prevent rotation, torque the four bolts at the transfer case yoke to specification in a criss-cross pattern using a torque wrench and 15mm socket. If using new torque-to-yield bolts, follow manufacturer installation instructions.
    Torque spec

    Driveshaft Flange Bolts (CV/U-Joint)75 Nm (55 lb-ft)
12. 12

    Torque front differential flange bolts
    Using a pry bar to prevent rotation, torque the four bolts at the front differential companion flange to specification in a criss-cross pattern using a torque wrench and 15mm socket. Verify all bolts are properly seated and torqued.
    Torque spec

    Driveshaft Flange Bolts (CV/U-Joint)75 Nm (55 lb-ft)
13. 13

    Check transfer case fluid level
    Check the transfer case fluid level through the fill plug. Add ATF+4 as necessary to bring the fluid level to the bottom of the fill plug hole. Verify the transfer case fluid capacity against the factory service manual (approximately 2.0 quarts for the NV271/NV273), but only replace what was lost during driveshaft removal.

Reassembly

1. Ensure all alignment marks are properly matched to prevent driveline vibration
2. Verify all torque specifications have been met using a calibrated torque wrench
3. Double-check that the center support bearing bracket is secure and properly oriented
4. Confirm no tools or parts are left under the vehicle

Verification

• Lower vehicle from jack stands and remove chocks
• Start engine and shift transfer case through all ranges (2H, 4H, 4L) to verify engagement
• Test drive vehicle at various speeds in 4WD mode and listen for vibrations, clunking, or unusual noises
• Check for fluid leaks around the transfer case output seal after test drive
• Verify smooth operation with no vibration at highway speeds in 2WD and 4WD modes
• Re-check all flange bolt torque after 50-100 miles of driving

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