2005 Ram 2500 Free Spin Install & Other Goodies

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legopnuematic

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Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
Thought I would make a thread detailing some work I’m helping my friend do on his 2005 Ram 2500, QCSB, 5.9 Cummins, 4x4.

A little backstory on the truck itself, as mentioned above it’s a 2005 Dodge Ram 2500, Quad Cab, short bed, 5.9 Cummins, automatic, 4x4. About 218K miles on it and is far above average condition for our area. The truck began life in California, then made its way to Missouri.

Paul, the previous, previous owner was a tradesman, lived in California did a lot of dirt bike stuff and used it to pull a 5th wheel camper, engine was supposedly inframed at some point, judging by some of the less than stellar quality of work done that has been found, hard to say what that “inframe” overhaul actually means. More on that later.

Paul had bought a new truck, sold this one to his friend, and our friend, Roger who lives in Missouri a little ways west of us. He kept it inside his shop and only drove it occasionally, so it stayed clean. Paul passed in 2019(?), his widow offered his current Ram to Roger, Roger bought it, and then offered this truck to my Friend, Shane, and Shane bought it from Roger.

Here is it dragging home what would become the frame donor for my Dodge. It is a genuine rust free truck. Shane is very anal about keeping it nice too, if it sits outside it gets covered, otherwise it is inside, gets washed before he puts it away, etc.
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For those that don’t know, the third gen Dodge trucks do not have any front axle disconnect like the 2nd gens do, so the front axle is always spinning the front driveshaft. And like most 4x4s made in the last thirty years, these use unit bearings.

He had wanted to go to a free spin setup with manual hubs and real spindles since he had found out about the front shaft spinning all the time shortly after purchasing the truck.

So that time has finally come. Dynatrac free spin kit will be installed, EMF rebuildable ball joints, front axle shaft seals, and he got a good deal (almost half off) on a Yukon limited slip for the rear that I will install.
 

legopnuematic

Licensed Junk Dealer
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Location
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First Name
Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
It happened that I decided to buy the four post at the time Shane decided to pull the trigger on the free spin setup and other parts, he was able to take advantage of sales at the time. This is the first project on the lift.

Pulling in the shop
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Lifting it up to look underneath and give a good overall preliminary inspection. One of the likely future repairs will be the overdrive housing on the 48re, they (and the 46,47s) are kind of well known for cracking and leaking, it is believed this one is cracked, as there is a consistent weeping of atf from that area. Or it might not be cracked. Considering that one of the previous mechanics/shops had managed to pinch the trans harness in between something that it had chaffed some wires and was shorting the harness causing interesting shifting conditions, you could watch the Moniter go 4,3,2,1 like a slot machine. With that in mind and in other places missing hardware, loose bolts, wrong bolts that were discovered I wouldn’t rule other possibilities out.

Also popped the trans inspection cover and found that it is not a billet torque converter, rather a stock type stamped front half, so the “build sheet” he was given with the truck might not be entirely truthful.
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Anyways, lowered down some and popped the fill plug, couple surprises on the magnet… and fluid was not up to level. Popped the cover and drained it, maybe a quart or two came out. It was clean fluid, but no where near what it should have.
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Part numbers on the fill plug. Looks to be parts of the carrier. Ring and pinion look ok, not chipped teeth or any signs of damage or carnage.

Not really sure what to think about that, or how it happened. Current plan is to clean and inspect everything and go from there.
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Letting it drip over night, moved the drain dolly to the rear and drained it, jacked the front up and put a saucepan under to catch any remaining drips.
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legopnuematic

Licensed Junk Dealer
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Location
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First Name
Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
Don’t anyone tell Gale Banks about the flat back rear differential cover!
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Pulled the wheels off, brake calipers hung to the side, rotors slid off.

Unbolted the unit bearings and passenger side slid out easy, drivers side took a couple of whacks but came free easy enough. Much easier than the donor axle under my Dodge.

Figured out the combination of cups for the trusty old ball joint press and pressed them out. They had been replaced at least once before with Moog problem solvers, not sure how many miles on them but there was definitely some wear in them. They came out easy enough. If was fun showing some of the tricks to this stuff, like loading the press up and giving it a firm whack with a mini sledge to relieve it, tighten up again, rinse and repeat.
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Ready for cleanup.
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The pile growing, removed the knuckle u joints to clean the shafts up
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And drivers side torn down and ready for cleanup. This side seal was weeping.
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A little more tear down up front, plenty of part cleaning and inspecting and reconditioning to do while we wait on some parts and the ball joints. Thankfully they were replaced before with standard sized ball joints, not oversized, so the bores mic’ed out ok to use standard sized replacements. Which is nice.
 

legopnuematic

Licensed Junk Dealer
Supporting Member
Joined
Oct 27, 2016
Posts
2,660
Reaction score
7,075
Location
MO
First Name
Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
Nice project! I'd love to put a free spin kit on my 06.

Is the tcase manual or electric shift?
It’s a NV271, manual shift
 

legopnuematic

Licensed Junk Dealer
Supporting Member
Joined
Oct 27, 2016
Posts
2,660
Reaction score
7,075
Location
MO
First Name
Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
I've seen to have caught whatever bug is going around here, not really been feeling my best, but trying to carry on anyways.

Some pictures of the goodies
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Doing a basic cleanup and paint on the axle ends. No pebble beach concourse here, but make things a little nicer than what we started with.
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While that was drying drained the transfer case as it's never been serviced in my friend's ownership. $30 for a jug of ATF+4 is a whole lot cheaper than a new/used/reman transfer case.
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I'd say it was about ready to be serviced.
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legopnuematic

Licensed Junk Dealer
Supporting Member
Joined
Oct 27, 2016
Posts
2,660
Reaction score
7,075
Location
MO
First Name
Spencer
Truck Year
1971, 1̶9̶7̶4, 1976, 1979,1̶9̶8̶5, 2002
Truck Model
Dart Swinger, Sierra 10, C10 Cheyenne, C10 Big Ten, Silverado 10, Ram 2500
Engine Size
225/6, 350 c.i., 350 c.i., 5.9l Cummins
Checked the backlash of the front and then pulled the carrier out to knock the axle seals out (or in I suppose). Still not sure what is the cause of the missing pieces of the carrier.
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Driver's side cleaned up and painted
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Axle shaft seals had been replaced before. Driver's side was weeping. Will be installing new AAM seals.
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TotalyHucked

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5.3
Man I hope you just caught a mild funk and not the Flu-A that's going around here. I knocked me on my ass for nearly a whole week, that's why I'm behind where I'd planned to be with my projects. Friday before Xmas through the Thursday after Xmas I was sick as a dog. I'm still not quite right, still got crap in my lungs and a cough I can't get rid of
 

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