I have read here tons but never posted a question. I have a 1999 Dodge 2500 with the Dana 60 axle. I have removed the passenger axle shaft and installed a new hub bearing rotor and U-joint. I noticed on the end of the inner shaft a plastic bushing that is in need of replacement so I'm waiting for that part. Here's the question? When I look up in the axle tube, I can see the clutch collar. It seems to have dropped down and just moving around in there. Is this normal or am I supposed to try and lift it up and put it on the intermediate shaft with the little stub. With the collar still in the shifting fork, does it usually have that much movement? All splines are good, after 200,000 miles the dang axle looks brand new, almost. When the plastic bushing arrives, I was just curious if it was ok to just take a dowel and move the collar into position and slide the axle back in. Don't want to button her back up and have problems. Any chance the collar would come out of the fork? Thanks. And many thanks to all that post, I have learned tons of info. on this site.

 

Should be in the 24 valve section.

 

If the collar has dropped off the inner shaft, the easiest fix is to just remove the disconnect assembly off the axle housing, remove the sliding collar from the fork and slide it onto the inner shaft. leave the disconnect off til the rest of the parts are assembled, then just align the fork with the collar and bolt the disconnect back on to the axle housing. Not a big deal at all.

Just pay attention to which way the collar faces when you remove it. It is a bit different from side to side.

 

Thanks Torquefan. Thats good to know. When the bushing comes in I can button her up. Thanks.

 

You're welcome.

 

In the future, make sure it's in 4wd before you pull the outer axle.

 

That's a good idea. Hope I don't have to pull that side for awhile. Thanks.