Transmission and transfer case DODGE RAM 1500 1998 2.G Workshop Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Differential & Driveline
5Brakes
6Clutch
7Cooling
8AAudio/Video
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8TNavigation/Telecommunication
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transmission and Transfer Case
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................1
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................1
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................2
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - TRANSFER CASE.........4
DESCRIPTION - AXLE...................4
DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID..................4
OPERATION - AUTOMATIC TRANSMISSION
FLUID...............................5FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES.....................5
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION........................6
MAINTENANCE SCHEDULES Ð 24±VALVE
CUMMINS TURBO DIESEL..............12
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 19
HOISTING
STANDARD PROCEDURE - HOISTING.......20
TOWING
STANDARD PROCEDURE - TOWING........21
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use good quality diesel fuel from a reputable sup-
plier in your Dodge truck. For most year-round ser-
vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If
the vehicle is exposed to extreme cold (below 0ÉF/-
18ÉC), or is required to operate at colder-than-normal
conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50%
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol-low the cold-weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane ªpremiumº diesel fuel may
offer improved cold starting and warm-up perfor-
mance.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
DRLUBRICATION & MAINTENANCE 0 - 1

tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-34ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle's coolant bottle to iden-
tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.
The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37ÉC (-35ÉF). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE
Recommended lubricant for the NV241 GENII,
NV271, NV243, NV244 GENII, and NV273 transfer
cases is MopartATF +4, Automatic Transmission
Fluid.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
FRONT AXLE
²C205F - MopartGear Lubricant 75W-90
²9 1/4 AA - MopartSynthetic Gear Lubricant
75W-90
REAR AXLE
²9 1/4 - MopartSynthetic Gear Lubricant 75W-
140
²10 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
²11 1/2 AA - MopartSynthetic Gear Lubricant
75W-90
NOTE: Trac-LokTdifferentials require Limited Slip
Additive in the lubricant. Trac-RiteŸ differentials
DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.
²NV3500 - MopartManual Transmission Lubri-
cant
²NV4500 - MopartSynthetic 75W85 Manual
Transmission Lubricant
²NV5600 - MopartManual Transmission Lubri-
cant
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
MopartATF +4, Automatic Transmission Fluid is
the recommended fluid for DaimlerChrysler auto-
matic transmissions.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
MopartATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.
0 - 4 LUBRICATION & MAINTENANCEDR
FLUID TYPES (Continued)

FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L 4.7 L (5.0 qts.)
4.7L 5.6 L (6.0 qts.)
5.7L 6.6 L (7.0 qts.)
5.9L DIESEL 11.4 L (12.0 qts.)
DESCRIPTION SPECIFICATION
COOLING SYSTEM
3.7L 15.4 L (16.2 qts.)**
4.7L 15.4 L (16.2 qts.)**
5.7L 15.4L (16.2 qts.)**
5.9L Diesel Engine 28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 48RE 3.8 L (4.0 qts.)
O-haul - 48RE 14-16L (29-33 pts.)L
Service Fill - 45RFE/
545RFE4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)
O-haul - 45RFE/545RFE 14-16 L (29-33 pts.)L
LDry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/
FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV3500 4X2 2.27 L (4.8 pts.)
NV3500 4X4 1.99 L (4.2 pts.)
NV4500 3.79 L (8.0 pts.)
NV5600 4.50 L (9.5 pts.)
TRANSFER CASE
NV241 GENII 1.6 L (3.4 pts.)
NV243 1.6 L (3.4 pts.)
NV244 GENII 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)
FRONT AXLE   .03 L (1 oz)
C205F 1.66 L (3.5 pts.)
9 1/4 AA 2.25 L (4.75 pts.)
DRLUBRICATION & MAINTENANCE 0 - 5
FLUID TYPES (Continued)

Once a Month
²Check tire pressure and look for unusual wear
or damage.
²Inspect the batteries and clean and tighten the
terminals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission
and transfer case (if equipped), add as needed.
²Check Filter MinderŸ. Replace air cleaner
filter element if necessary.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change the engine oil filter.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the CV joints (if equipped) and front sus-
pension components.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
Tire Rotation
²Rotate the tires every 7,500 miles (12 000 km).
Engine Oil Change Chart Notes
²LTier 1 EPA (250 hp or 305 hp) Engines Only
(see engine data label for your engine type)
²² California LEV (235 hp) Engines Only (see
engine data label for your engine type)
Schedule ªBº
Follow schedule ªBº if you usually operate your
vehicle under one or more of the following conditions.
²Day or night temperatures are below 0É C (32É
F).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 16 km (10 miles).
²More than 50% of your driving is at sustained
high speeds during hot weather, above 32É C (90É F).
²Trailer towing.
²Taxi, police, or delivery service (commercial ser-
vice).
²Off-road or desert operation.
Miles 3,750 7,500 11,250 15,000 18,750
(Kilometers) (6 000) (12 000) (18 000) (24 000) (30 000)
Change engine oil and engine oil filter. X² XL²X²XL²X²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Inspect water pump weep hole for
blockage.X
Replace fuel filter element. Clean the water
in fuel sensor.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Inspect brake linings.X
Inspect and adjust parking brake if
necessary.X
DRLUBRICATION & MAINTENANCE 0 - 13
MAINTENANCE SCHEDULES (Continued)

Miles 22,500 26,250 30,000 33,750 37,500
(Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)
Change engine oil and engine oil filter. XL²X²XL²X² XL²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXX
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep hole for
blockage.X
Replace fuel filter element. Clean the water
in fuel sensor.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Check transfer case fluid level (4X4). X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands.X
Miles 41,250 45,000 48,750 52,500 56,250
(Kilometers) (66 000) (72 000) (78 000) (84 000) (90 000)
Change engine oil and engine oil filter. X² XL²X²XL²X²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Inspect drive belt, replace as required. X
Inspect water pump weep hole for
blockage.X
Replace fuel filter element. Clean the water
in fuel sensor.X
Inspect brake linings. X
Inspect and adjust parking brake if
necessary.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
0 - 14 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

Miles 60,000 63,750 67,500 71,250 75,000
(Kilometers) (96 000) (102 000) (108 000) (114 000) (120 000)
Change engine oil and engine oil filter. XL²X²XL²X² XL²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXX
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep hole for
blockage.XX
Replace fuel filter element. Clean the water
in fuel sensor.XX
Inspect front wheel bearings. X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect brake linings. X X
Inspect and adjust parking brake if
necessary.XX
Drain and refill transfer case fluid (4X4). X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands.X
Miles 78,750 82,500 86,250 90,000 93,750
(Kilometers) (126 000) (132 000) (138 000) (144 000) (150 000)
Change engine oil and engine oil filter. X² XL²X²XL²X²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XX
Inspect drive belt, replace as required. X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Check transfer case fluid level (4X4). X
Inspect fan hub.X
Inspect damper.X
Inspect water pump weep hole for
blockage.X
Replace fuel filter element. Clean the water
in fuel sensor.X
Inspect front wheel bearings. X
Inspect brake linings.X
Inspect and adjust parking brake if
necessary.X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands.X
DRLUBRICATION & MAINTENANCE 0 - 15
MAINTENANCE SCHEDULES (Continued)

Miles 97,500 100,000 101,250 105,000 108,750 112,500
(Kilometers) (156 000) (160 000) (162 000) (168 000) (174 000) (180 000)
Change engine oil and engine
oil filter.XL²X²XL²X² XL²
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXX
Flush and replace engine
coolant.X
Inspect drive belt, replace as
required.X
Inspect water pump weep
hole for blockage.X
Replace fuel filter element.
Clean the water in fuel sensor.X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Inspect brake linings. X
Inspect and adjust parking
brake if necessary.X
Miles 116,250 120,000 123,750 127,500 131,250 135,000
(Kilometers) (186 000) (192 000) (198 000) (204 000) (210 000) (216 000)
Change engine oil and engine
oil filter.X² XL²X²XL²X² XL²
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXX
Clean engine air filter canister.X
Adjust valve lash clearance.X
Inspect drive belts, replace as
required.X
Drain and refill transfer case
fluid (4X4).X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep
hole for blockage.XX
Replace fuel filter element.
Clean the water in fuel sensor.XX
Inspect front wheel bearings. X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect brake linings. X X
Inspect and adjust parking
brake if necessary.XX
Drain and refill automatic
transmission fluid. Replace
filter and adjust bands.X
0 - 16 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

Miles 82,500 90,000 97,500 100,000 105,000
(Kilometers) (132 000) (144 000) (156 000) (160 000) (168 000)
[Months] [66] [72] [78] [84]
Change engine oil and engine oil filter. X² XL²X² XL²
Lubricate outer tie rod ends 2500/3500
(4X4) models only.XXXX X
Flush and replace engine coolant, if not
done at 60 mos.X
Check transfer case fluid level (4X4). X
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
Inspect water pump weep hole for
blockage.XX
Replace fuel filter element. Clean the water
in fuel sensor.XX
Inspect front wheel bearings. X
Inspect brake linings. X
Inspect and adjust parking brake if
necessary.X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands.X
Miles 112,500 120,000 127,500 135,000 142,500 150,000
(Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000)
[Months] [90] [96] [102] [108] [114] [150]
Change engine oil and engine
oil filter.X² XL²X²XL²X² XL²
Lubricate outer tie rod ends
2500/3500 (4X4) models only.XXXXX X
Flush and replace engine
coolant, if it has been 160
000 km (100, 000 miles) or 60
months since last change.X
Inspect drive belt, replace as
required.XX
Drain and refill transfer case
fluid (4X4).X
Check tranfer case fluid level
(4X4).X
Inspect fan hub. X X
Inspect damper. X X
Inspect water pump weep
hole for blockage.XXX
Replace fuel filter element.
Clean the water in fuel
sensor.XXX
0 - 18 LUBRICATION & MAINTENANCEDR
MAINTENANCE SCHEDULES (Continued)

(10) Start engine and check vibration. If there is
little or no change move the clamp to the next posi-
tions. Repeat the vibration test.
NOTE: If there is no difference in vibration at this
positions, the vibration may not be the propeller
shaft.
(11) If vibration decreased, install a second clamp
(Fig. 2) and repeat the test.
(12) If additional clamp causes an additional vibra-
tion, separate the clamps 1/2 inch above and below
the mark. Repeat the vibration test (Fig. 3).
(13) Increase distance between the clamp screws
and repeat test, until the least amount of vibration is
noticed. Bend the slack end of the clamps so screws
will not loosen.
(14) If vibration remains unacceptable, repeat the
procedure to the front end of the propeller shaft.
(15) Install wheels and lower vehicle.PROPELLER SHAFT RUNOUT
(1) Clean propeller shaft surface, where dial indi-
cator will contact the shaft.
(2) Install dial indicator perpendicular to the shaft
surface.
(3) Measure runout at the center and ends of the
shaft away from weld areas, so weld process does not
affect measurements.
(4) Refer to Runout Specifications chart.
(5) If runout is out of specification, index the shaft
180É and take shaft runout measurements again.
(6) If runout is now within specifications, mark
shaft and yokes for proper orientation.
(7) If runout is not within specifications, verify
runout of the transmission/transfer case and axle are
within specifications. Correct as necessary and mea-
sure propeller shaft runout again.
(8) Replace propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
Front of Shaft 0.030 in. (0.76 mm)
Center of Shaft 0.015 in. (0.38 mm)
Rear of Shaft 0.030 in. (0.76 mm)
note:
Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
This procedure applies to front and rear propeller
shafts.
NOTE: To obtain output angle (A) on the front pro-
peller shaft equipped with a C/V joint, place incli-
nometer on machined surface of the C/V joint.
(1) Place vehicle in Neutral.
(2) Raise vehicle and support the axles as level as
possible.
(3) Remove universal joint snap rings if equipped,
so Inclinometer 7663 base sits flat.
(4) Rotate shaft until transmission/transfer case
output yoke bearing is facing downward.
NOTE: Always take measurements from front to
rear and on the same side of the vehicle.
(5) Place inclinometer on yoke bearing cap or pin-
ion flange ring (A) parallel to the shaft (Fig. 4). Cen-
ter bubble in sight glass and record measurement.
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1-1¤2INCH
DRPROPELLER SHAFT 3 - 3
PROPELLER SHAFT (Continued)