Fig DODGE RAM 1500 1998 2.G Workshop Manual

OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm  0.5mm
2 - POSITION 2 - 12mm  0.5mm
3 - POSITION 3 - 14mm  0.5mm
4 - POSITION 4 - 16mm  0.5mm
5 - POSITION 5 - 18mm  0.5mm
6 - POSITION 6 - 20mm 0.5mm - FULL EXTENSION
DRTRANSFER CASE - NV241 GENII 21 - 443
POSITION SENSOR (Continued)

SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Raise and support the vehicle.
(3) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(4) Lower vehicle.
(5) Remove transfer case shifter knob cap.
(6) Remove nut holding shifter knob to shift lever.
(7) Remove shifter knob.
(8) Remove the shift boot from the shifter console.
(9) Remove the bolts securing the shifter mecha-
nism to the floor pan (Fig. 88).
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 88 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 444 TRANSFER CASE - NV241 GENIIDR

INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 89).
(2) Position shift lever in vehicle.
(3) Install the bolts to hold the shifter mechanism
to the floor pan.
(4) Raise vehicle.
(5) Verify that the transfer case is still in the 2H
position. The 2H detent position on the transfer case
shift arm is the second position from full forward.
(6) Install trunnion to shift lever, if necessary.
(7) Install shift rod to trunnion, if necessary.(8) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(9) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(10) Lower vehicle.
(11) Install the transfer case shifter console.
(12) Install the shifter boot and the shifter knob
onto the shifter lever.
(13) Install nut to hold shifter knob to shift lever.
(14) Install shifter knob cap.
(15) Verify transfer case operation.
Fig. 89 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV241 GENII 21 - 445
SHIFT LEVER (Continued)

ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion.
(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion. Lubricate the shift rod
and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H
detent position. The 2H detent position on the trans-
fer case shift arm is the second position from full for-
ward.
(6) Align the adjustment locating hole on the lower
shifter lever with the adjustment channel on the
shifter bracket assembly (Fig. 90).(7) Insert an appropriately sized pin through into
the adjustment channel and through the locating
hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N´m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans-
fer case shifts into and operates properly in all
ranges.
Fig. 90 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 446 TRANSFER CASE - NV241 GENIIDR
SHIFT LEVER (Continued)

TRANSFER CASE - NV271
TABLE OF CONTENTS
page page
TRANSFER CASE - NV271
DESCRIPTION........................447
OPERATION..........................448
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV271.......................448
REMOVAL............................450
DISASSEMBLY........................450
CLEANING...........................459
INSPECTION.........................459
ASSEMBLY...........................461
INSTALLATION........................473
SPECIFICATIONS
TRANSFER CASE - NV271.............473
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........474
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................476INSTALLATION........................476
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................476
FRONT OUTPUT SHAFT SEAL
REMOVAL............................477
INSTALLATION........................477
POSITION SENSOR
DESCRIPTION........................477
OPERATION..........................477
REMOVAL............................478
INSTALLATION........................478
SHIFT LEVER
REMOVAL............................479
INSTALLATION........................480
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER..........481
TRANSFER CASE - NV271
DESCRIPTION
The NV271 transfer case is a part-time transfer
case with a low-range gear system. It provides three
operating ranges plus a NEUTRAL position. The low
range position provides a gear reduction ratio of
2.72:1 for increased low speed torque capability.
The gear cases and extension are all of aluminum
(Fig. 1). Drive sprockets and an interconnecting drive
chain are used to transmit engine torque to the front/
rear propeller shafts. The mainshaft, input gear and
front output shaft are supported by ball and needle
bearings.
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DRTRANSFER CASE - NV271 21 - 447

IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
OPERATING RANGE
Transfer case operating ranges are:
²2H (2-wheel drive)
²4H (4-wheel drive)
²4LO (4-wheel drive low range
The 2H range is for use on any road surface at any
time.
The 4H and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is covered by
ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 448 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.
(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
COMPANION FLANGE AND EXTENSION HOUSING
(1) Install two bolts 180É apart into the front out-
put shaft companion flange.
(2) Place holder over the bolts and against the
companion flange (Fig. 3).
(3) Remove and discard the front companion flange
nut.
(4) Remove the companion flange from the front
output shaft. It may be necessary to use Flange
puller 8992 to remove the companion flange.
(5) Use a suitable chisel or pry tool to remove the
rear extension housing dust boot (Fig. 4).
(6) Use a suitable chisel or pry tool to remove the
rear extension housing seal.
Fig. 3 Remove Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
Fig. 4 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
21 - 450 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(7) Remove rear extension bolts (Fig. 5).
(8) Remove rear extension housing (Fig. 6). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.OIL PUMP AND REAR CASE
(1) Disengage the oil pump pick-up tube (Fig. 7)
from the oil pump.
NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.
(2) Remove the oil pump (Fig. 8).
Fig. 5 Remove Extension Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
Fig. 6 Remove Extension Housing
1 - REAR CASE HALF
2 - EXTENSION HOUSING
Fig. 7 Disengage The Oil Pick-up From Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
Fig. 8 Remove Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
DRTRANSFER CASE - NV271 21 - 451
TRANSFER CASE - NV271 (Continued)

(3) Remove rear case-to-front case bolts (Fig. 9).
(4) Remove the rear output shaft bearing inner
snap-ring (Fig. 10) from the output shaft using suit-
able snap-ring pliers.
(5) Remove the rear output shaft bearing inner
snap-ring (Fig. 11) from the output shaft.
(6) Loosen rear case with pry tool to break sealer
bead. Insert tool at each end of case (Fig. 12).
Fig. 9 Remove Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 10 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 11 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 12 Separate Front and Rear Case Halves
1 - FRONT CASE HALF
2 - REAR CASE HALF
21 - 452 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(7) Unseat rear case from alignment dowels.
(8) Remove the rear case from the front case (Fig.
13).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove the oil pick-up tube (Fig. 14) and
screen from the front case half.
(2) Remove the shift rail spring (Fig. 15).(3) Remove the front output shaft drive sprocket
retaining ring (Fig. 16).
Fig. 16 Remove Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 14 Remove Oil Pick-Up Tube and Screen
1 - FRONT CASE HALF
2 - OIL SCREEN
3 - PICK-UP TUBE
Fig. 15 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
DRTRANSFER CASE - NV271 21 - 453
TRANSFER CASE - NV271 (Continued)