tire DODGE RAM 1500 1998 2.G Workshop Manual

GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
GEAR - INDEPENDENT FRONT SUSPENSION
DESCRIPTION.........................17
REMOVAL.............................17
INSTALLATION.........................18
SPECIFICATIONS
TORQUE CHART......................19BUSHING
REMOVAL.............................19
INSTALLATION.........................19
GEAR - INDEPENDENT FRONT
SUSPENSION
DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made
up of two main components, the pinon shaft and the
rack. The gear cannot be adjusted or internally ser-
viced. If a malfunction or a fluid leak occurs, the gear
must be replaced as an assembly.
REMOVAL
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
(1) Lock the steering wheel.(2) Drain and siphon the power steering fluid from
the reservoir.
(3) Raise the vehicle.
(4) Remove and discard the steering coupler pinch
bolt.
(5) Remove the power steering hoses from the rack
& pinion.
(6) Remove the tire and wheel assembly.
(7) Remove the tie rod end nuts and separate tie
rod ends from the knuckles with Special tool 8677
(Refer to 19 - STEERING/LINKAGE/TIE ROD END -
REMOVAL).
(8) Remove the skid plate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKID PLATE -
REMOVAL).
(9) Remove the rack & pinion mounting bolts. (Fig.
2) & (Fig. 3)
(10) Remove the rack & pinion from the vehicle.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR MOUNTING BOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
DRGEAR - INDEPENDENT FRONT SUSPENSION 19 - 17

INSTALLATION
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
NOTE: In the frame there is two holes for the
mounting of the steering gear one is slotted and
one is round, When tightening the gear to specifi-
cations make sure to tighten the mounting bolt with
the hole first to avoided movement of the steering
gear.
(1) Install the gear on the front crossmember and
tighten the mounting bolts to 319 N´m (235 ft. lbs.).
(Fig. 4) & (Fig. 3).
(2) Slide the shaft coupler onto the gear. Install
newpinch bolt and tighten to 49 N´m (36 ft. lbs.).
(3) Clean and dry the tie rod end studs and the
knuckle tapers.
(4) Install the tie rod ends into the steering knuck-
les and tighten the nuts to 61 N´m (45 ft. lbs.) thenan additional 90É. (Refer to 19 - STEERING/LINK-
AGE/TIE ROD END - INSTALLATION).
(5) Install the pressure power steering hose to the
steering gear and tighten to 32 N´m (23 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL-
LATION).
(6) Install the return power steering hose to the
steering gear and tighten to 71 N´m (52 ft. lbs.).
(Refer to 19 - STEERING/PUMP/HOSES - INSTAL-
LATION).
(7) Install the front skid plate (Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT SKID PLATE
- INSTALLATION).
(8) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Remove the support and lower the vehicle.
(10) Fill the system with fluid, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
(11) Adjust the toe position. (Refer to 2 - SUSPEN-
SION/WHEEL ALIGNMENT - STANDARD PROCE-
DURE).
Fig. 3 STEERING GEAR 4X2
1-SWAYBAR
2 - STEERING GEAR
3 - LEFT OUTER TIE ROD END
4 - LOWER CONTROL ARMS
5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)
Fig. 4 STEERING GEAR 4X4
1 - FRONT AXLE
2 - STEERING GEAR MOUNTING NUTS & BUSHINGS
19 - 18 GEAR - INDEPENDENT FRONT SUSPENSIONDR
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)

LINKAGE - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
LINKAGE - INDEPENDENT FRONT
SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END ................................32TIE ROD END
REMOVAL - OUTER TIE ROD END..........32
INSTALLATION - OUTER TIE ROD END......33
LINKAGE - INDEPENDENT
FRONT SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.
(1) Raise the front of the vehicle. Place safety floor
stands under both lower control arms as far outboard
as possible. Lower the vehicle to allow the stands to
support some or all of the vehicle weight.
(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the
outer tie rod end.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the outer tie rod
end.
(5) Position a pry bar in order to pry downwards
on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall
the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).
TIE ROD END
REMOVAL - OUTER TIE ROD END
NOTE: Do not twist the boot anytime during
removal or installation.
(1) Loosen the jam nut.
(2) Remove the outer tie rod end nut from the ball
stud.
(3) Separate the tie rod ball stud from the knuckle
with Remover 8677 (Fig. 1).
(4) Unthread the outer tie rod end from the inner
tie rod.
Fig. 1 TIE ROD SEPARATION
1 - TIE ROD END
2 - SPECIAL TOOL 8677
19 - 32 LINKAGE - INDEPENDENT FRONT SUSPENSIONDR

REVERSE POWERFLOW
When the gear selector is moved into the
REVERSE position (Fig. 5), the front clutch and the
rear band are applied. With the application of the
front clutch, engine torque is applied to the sun gear,
turning it in a clockwise direction. The clockwise
rotation of the sun gear causes the rear planet pin-
ions to rotate against engine rotation in a counter-
clockwise direction. The rear band is holding the low
reverse drum, which is splined to the rear carrier.
Since the rear carrier is being held, the torque fromthe planet pinions is transferred to the rear annulus
gear, which is splined to the output shaft. The output
shaft in turn rotates with the annulus gear in a
counterclockwise direction giving a reverse gear out-
put. The entire transmission of torque is applied to
the rear planetary gearset only. Although there is
torque input to the front gearset through the sun
gear, no other member of the gearset is being held.
During the entire reverse stage of operation, the
front planetary gears are in an idling condition.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
21 - 136 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(1) Disconnect battery negative cable.
(2) Raise vehicle.
(3) Remove the transfer case skid plate (Fig. 12), if
equipped.(4) Disconnect and lower or remove necessary
exhaust components.
(5) Remove engine-to-transmission struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(7) Disconnect and remove the crankshaft position
sensor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain the sensor attaching bolts.
(8) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(9) Remove torque converter access cover.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Disconnect wires from the transmission range
sensor and transmission solenoid connector.
(13) Disconnect gearshift cable (Fig. 13) from the
transmission.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
21 - 158 AUTOMATIC TRANSMISSION - 48REDR
AUTOMATIC TRANSMISSION - 48RE (Continued)

OVERDRIVE UNIT
REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Remove transfer case, if equipped.
(4) Mark propeller shaft universal joint(s) and axle
pinion yoke, or the companion flange and flange
yoke, for alignment reference at installation, if neces-
sary.
(5) Disconnect and remove the rear propeller shaft,
if necessary. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(7) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag-
nosis indicated overdrive problems only, remove just
the overdrive unit.
(8) Support transmission with transmission jack.
(9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 118).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.(11) If overdrive unit does not require service,
immediately insert Alignment Tool 6227-2 in splines
of planetary gear and overrunning clutch to prevent
splines from rotating out of alignment. If misalign-
ment occurs, overdrive unit will have to be disassem-
bled in order to realign splines.
(12) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul will
be necessary.
(16) If overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent
accidental misalignment of planetary gear and over-
running clutch splines.
DISASSEMBLY
(1) Remove transmission speed sensor and o-ring
seal from overdrive case (Fig. 119).
(2) Remove overdrive piston thrust bearing (Fig.
120).
Fig. 118 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 119 Transmission Speed Sensor
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
21 - 218 AUTOMATIC TRANSMISSION - 48REDR

(5) Remove sun gear and driving shell as assembly
(Fig. 197).
(6) Remove tabbed thrust washer from rear plane-
tary gear (Fig. 198). Note washer position on gear for
assembly reference.
(7) Remove rear planetary gear and rear annulus
gear from intermediate shaft (Fig. 199).
(8) Remove thrust washer from rear planetary
gear (Fig. 200).
INSPECTION
Inspect the planetary gear sets and annulus gears.
The planetary pinions, shafts, washers, and retaining
pins are serviceable. However, if a pinion carrier is
damaged, the entire planetary gear set must be
replaced as an assembly.Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash-
ers if cracked, scored or worn.
Inspect the machined surfaces of the intermediate
shaft. Be sure the oil passages are open and clear.
Replace the shaft if scored, pitted, or damaged.
Inspect the sun gear and driving shell. If either
component is worn or damaged, remove the sun gear
rear retaining ring and separate the sun gear and
thrust plate from the driving shell. Then replace the
necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
Fig. 197 Sun Gear And Driving Shell Removal
1 - INTERMEDIATE SHAFT
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 198 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 199 Rear Planetary And Annulus Gear Removal
1 - INTERMEDIATE SHAFT
2 - REAR ANNULUS GEAR
3 - REAR PLANETARY GEAR
Fig. 200 Rear Annulus Thrust Washer Removal
1 - REAR ANNULUS GEAR
2 - THRUST WASHER
DRAUTOMATIC TRANSMISSION - 48RE 21 - 243
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(10) Install the spacer ring and wave spring into
the retainer. Be sure spring is completely seated in
retainer groove.
(11) Install pressure plate (Fig. 214). Ridged side
of plate faces downward (toward piston) and flat side
toward clutch pack.
(12) Install first clutch disc in retainer on top of
pressure plate. Then install a clutch plate followed
by a clutch disc until entire clutch pack is installed
(4 discs and 3 plates are required) (Fig. 214).
(13) Install the reaction plate.
(14) Install selective snap-ring. Be sure snap-ring
is fully seated in retainer groove.
(15) Using a suitable gauge bar and dial indicator,
measure clutch pack clearance (Fig. 216).
(a) Position gauge bar across the clutch drum
with the dial indicator pointer on the pressure
plate (Fig. 216).
(b) Using two small screw drivers, lift the pres-
sure plate and release it.
(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 -
0.036 in.). If clearance is incorrect, steel plates, discs,
selective snap ring and pressure plates may have to
be changed.
The selective snap ring thicknesses are:²0.107 - 0.109 in.
²0.098 - 0.100 in.
²0.095 - 0.097 in.
²0.083 - 0.085 in.
²0.076 - 0.078 in.
²0.071 - 0.073 in.
²0.060 - 0.062 in.
(16) Coat rear clutch thrust washer with petro-
leum jelly and install washer over input shaft and
into clutch retainer (Fig. 217). Use enough petroleum
jelly to hold washer in place.
(17) Set rear clutch aside for installation during
final assembly.
Fig. 215 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM
Fig. 216 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4-STAND
5 - REAR CLUTCH
6 - GAUGE BAR
Fig. 217 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER
21 - 250 AUTOMATIC TRANSMISSION - 48REDR
REAR CLUTCH (Continued)

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 sectoroperates 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 -
NV241 GENII
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.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 416 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
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.
DRTRANSFER CASE - NV241 GENII 21 - 417
TRANSFER CASE - NV241 GENII (Continued)