Fig DODGE RAM 1500 1998 2.G Workshop Manual

(12) Install new o-ring on detent plug (Fig. 69).
(13) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).(1) Position the shift motor and mode sensor
assembly (Fig. 71) onto the transfer case.
(2) Install the bolts (Fig. 72) to hold the shift
motor and mode sensor assembly to the transfer
case. Tighten the bolts to 16-25 N´m (12-18 ft. lbs.).
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
Fig. 71 Install Shift Motor Assembly Onto Transfer
Case
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
Fig. 72 Install Shift Motor Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
3 - BOLTS
DRTRANSFER CASE - NV273 21 - 563
TRANSFER CASE - NV273 (Continued)

(3) Install mainshaft into the transfer case (Fig.
73). Guide mainshaft through the mode and range
sleeves and into the input gear.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 74) into the
front output shaft front bearing.
(2) Install the front output shaft bearing inner
snap-ring (Fig. 75) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front drive sprocket in drive chain.
(5) Install drive chain around rear drive sprocket.(6) Position rear drive sprocket (Fig. 76) over the
output shaft and lower the sprocket and chain
assembly until the front sprocket is positioned over
the front output shaft.
(7) Align the splines in the sprockets to the splines
on the output shafts and install the sprockets onto
the output shafts.
Fig. 73 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 74 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 75 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 76 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
21 - 564 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(8) Install front sprocket retaining ring (Fig. 77).
(9) Install rear sprocket retaining ring (Fig. 78).(10) Insert magnet in front case pocket (Fig. 79).
REAR CASE
(1) Install the oil pick-up tube and screen into the
rear case half.
(2) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of front case. Keep sealer
bead width to maximum of 3/16 inch. Do not use
excessive amount of sealer as excess will be displaced
into case interior.
(3) Align mainshaft with the rear output shaft
bearing and align shift rail with bore in rear case.
Then install rear case (Fig. 80). Verify that the case
alignment dowels correctly seat into their mating
recesses.
Fig. 77 Install Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 78 Install Rear Output Shaft Sprocket Retaining
Ring
1 - REAR OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 79 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 80 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
DRTRANSFER CASE - NV273 21 - 565
TRANSFER CASE - NV273 (Continued)

(4) Install 4-5 rear case-to front case bolts (Fig. 81)
to hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts. Case
could be cracked if shaft rail or dowels are mis-
aligned.
(5) Tighten bolts to 27-34 N´m (20-25 ft. lbs.),
(6) Install rear output bearing inner snap-ring
(Fig. 82) to output shaft.OIL PUMP AND REAR EXTENSION
(1) Install the oil pump (Fig. 83) onto the output
shaft.
(2) Engage the oil pump pick-up tube (Fig. 84) into
the oil pump. Verify that the pick-up tube o-ring is
on the tube and is correctly installed to the oil pump.
Fig. 81 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 82 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 83 Install Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
Fig. 84 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
21 - 566 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(3) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(4) Install extension housing (Fig. 85) onto the
rear case half.
(5) Install rear extension bolts (Fig. 86). Tighten
the bolts to 27-34 N´m (20-25 ft.lbs.).(6) Install the extension housing dust boot and
seal assembly with Installer 9037 and Handle C-4171
(Fig. 87).
Fig. 85 Install Extension Housing
1 - REAR CASE HALF
2 - EXTENSION HOUSING
Fig. 86 Install Extension Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
Fig. 87 Install Extension Housing Seal
1 - EXTENSION HOUSING
2 - HANDLE C-4171
3 - INSTALLER 9037
DRTRANSFER CASE - NV273 21 - 567
TRANSFER CASE - NV273 (Continued)

(7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
companion flange (Fig. 88).
(10) Install a new front companion flange nut.
Tighten the companion flange nut to 176-271 N´m
(130-200 ft.lbs.).
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case onto the transmission.
(5) Install and tighten transfer case attaching nuts
to 27-34 N´m (20-25 ft. lbs.) torque.
(6) Connect the vent hose.
(7) Connect the shift motor and mode sensor wir-
ing connectors. Secure wire harness to clips on trans-
fer case.
(8) Align and connect the propeller shafts.
(9) Fill transfer case with correct fluid. (Refer to
21 - TRANSMISSION/TRANSFER CASE/FLUID -
STANDARD PROCEDURE)
(10) Install skid plate, if equipped.(11) Remove transmission jack and support stand.
(12) Lower vehicle and verify transfer case shift
operation.
SPECIFICATIONS
TRANSFER CASE - NV273
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Support, Sector 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-25 12-18 -
Nut, Companion Flange 176-271 130-200 -
Fig. 88 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
21 - 568 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

EXTENSION HOUSING SEAL
AND DUST BOOT
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Use a suitable chisel or pry tool to remove the
rear extension housing dust boot (Fig. 89).
(4) Use a suitable chisel or pry tool to remove the
rear extension housing seal.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Install the extension housing dust boot and
seal assembly with Installer 9037 and Handle C-4171
(Fig. 90).
(3) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(4) Verify proper transfer case fluid level.
(5) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 91).
(1) Raise vehicle.(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
Fig. 89 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
Fig. 90 Install Extension Housing Seal
1 - EXTENSION HOUSING
2 - HANDLE C-4171
3 - INSTALLER 9037
Fig. 91 Drain and Fill Locations
1 - FILL HOLE
2 - DRAIN HOLE
DRTRANSFER CASE - NV273 21 - 571

(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, Automatic Transmis-
sion fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Remove the front propeller shaft (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL).
(2) Install two bolts 180É apart into the front out-
put shaft companion flange.
(3) Place holder over the bolts and against the
companion flange (Fig. 92).
(4) Remove and discard the front companion flange
nut.
(5) Remove the companion flange from the front
output shaft. It may be necessary to use Flange
puller 8992 to remove the companion flange.
(6) Using a screw and a slide hammer, remove the
front output shaft seal.
INSTALLATION
(1) Install the new front output shaft seal with
Installer MB991168A.
(2) Install the front companion flange onto the
front output shaft.
(3) Install two bolts 180É apart into the front out-
put shaft companion flange.
(4) Place holder over the bolts and against the
companion flange (Fig. 93).
(5) Install a new front companion flange nut.
Tighten the companion flange nut to 258-312 N´m
(190-230 ft.lbs.).
(6) Install front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION).
Fig. 92 Remove Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
Fig. 93 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
21 - 572 TRANSFER CASE - NV273DR
FLUID (Continued)

MODE SENSOR
DESCRIPTION
The transfer case mode sensor (Fig. 94) is an elec-
tronic device whose output can be interpreted to indi-
cate the shift motor shaft's rotary position. The
sensor consists of a magnetic ring and four Hall
Effect Transistors to create a 4 channel digital device
(non-contacting) whose output converts the motor
shaft position into a coded signal. The TCCM must
supply 5VDC (+/- 0.5v) to the sensor and monitor the
shift motor position. The four channels are denoted
A, B, C, and D. The sensor is mechanically linked to
the shaft of the cam which causes the transfer case
shifting. The mode sensor draws less than 53 mA.
OPERATION
During normal vehicle operation, the Transfer Case
Control Module (TCCM) monitors the mode sensor
outputs at least every 250 (+/-50) milliseconds when
the shift motor is stationary and 400 microseconds
when the shift motor is active. A mode sensor signal
between 3.8 Volts and 0.8 Volts is considered to be
undefined.
Refer to SECTOR ANGLES vs. TRANSFER CASE
POSITION for the relative angles of the transfer case
shift sector versus the interpreted transfer case gear
operating mode. Refer to MODE SENSOR CHAN-
NEL STATES for the sensor codes returned to the
TCCM for each transfer case mode sensor position.
The various between gears positions can also be
referred as the transfer case's coarse position. These
coarse positions come into play during shift attempts.SECTOR ANGLES VS. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CHANNEL STATES
Transfer Case
Angle (degrees)Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
Between Gears H H L H
+40 (4LO) H H L L
Between Gears H H L H
Between Gears H L L H
+20 (NEUTRAL) H L L L
Between Gears H L L H
Between Gears H L H H
0 (2WD/AWD) H L H L
Between Gears H L H H
Between Gears L L H H
-20 (4HI) L L H L
Between Gears L L H H
Between Gears L H H H
Fig. 94 Mode Sensor
1 - MODE SENSOR
DRTRANSFER CASE - NV273 21 - 573

SELECTOR SWITCH
DESCRIPTION
The selector switch assembly (Fig. 95) is mounted
in the left side of the vehicle's Instrument Panel (IP)
and consists of a rotary knob connected to a resistive
network for the mode and range shift selections. Also
located in this assembly is a recessed, normally open
momentary switch for making shifts into and out of
transfer case NEUTRAL. A pen, or similar instru-
ment, is used to make a NEUTRAL shift selection,
thus reducing the likelihood of an inadvertent shift
request.
The selector switch also contains four light emit-
ting diode's (LED's) to indicate the transfer case posi-
tion and whether a shift is in progress.
OPERATION
As the position of the selector switch varies, the
resistance between the Mode Sensor supply voltage
pin and the Mode Sensor output will vary. Hardware,
software, and calibrations within the Transfer Case
Control Module (TCCM) are provided that interpret
the selector switch resistance as given in the table
below: SELECTOR SWITCH INTERPRETATION
SELECTOR SWITCH INTERPRETATION
Step Resistance
Range (ohms)Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4HI
E 3050-5950 2WD (Default)
F 9.5-12.5K In between
positions
G >15.5K Open
For resistances between the ranges B-E shown for
each valid position (T-Case NEUTRAL, 4LO, 4HI,
2WD), the TCCM may interpret the resistance as:
²either of the neighboring valid positions.
²as an invalid fault position.
For resistances between the ranges E and F shown
for 2WD and in-between positions, the TCCM may
interpret the resistance as:
²the 2WD position.
²an invalid fault position.
²a valid in-between position.
For resistances between the ranges F and G shown
for in-between positions and fault condition (open),
the TCCM may interpret the resistance as:
²a valid in-between position.
²an invalid fault position.
For resistances between the ranges A and B shown
for the fault condition (short) and , T-Case NEU-
TRAL, the TCCM may interpret the resistance as:
²the T-Case NEUTRAL position.
²an invalid fault position.
The LED's in the selector assembly are illuminat-
ed/flashed in the following manner to indicate a par-
ticular condition or state.
²A solidly illuminated LED indicates a success-
fully completed shift and the current operating mode
of the transfer case. While a shift has been requested
but not yet completed, the LED for the desired trans-
fer case position is flashed.
²A flashing operating mode LED for the desired
gear indicates that a shift to that position has been
requested, but all of the driver controllable conditions
Fig. 95 Transfer Case Selector Switch
1 - SELECTOR SWITCH
21 - 574 TRANSFER CASE - NV273DR