transmission fluid DODGE RAM 1500 1998 2.G Workshop Manual

(10) Remove the rear output shaft bearing from
the rear case using Remover/Installer 8684 and Han-
dle C-4171 (Fig. 49).
(11) Install the rear output shaft bearing (Fig. 50)
into the rear case using Remover/Installer 6953 and
Handle C-4171.INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 51)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 51). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
Fig. 49 Remove Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 8684
3 - HANDLE C-4171
Fig. 50 Install Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 6953
3 - HANDLE C-4171
Fig. 51 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
21 - 498 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

(6) Align and install low range/input gear assem-
bly in front case (Fig. 52). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 53).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install the mode hub (Fig. 54) onto the output
shaft.
(3) Install the mode hub retaining ring (Fig. 55)
onto the output shaft.
Fig. 52 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 53 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 54 Install Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 55 Install Mode Hub Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
DRTRANSFER CASE - NV243 21 - 499
TRANSFER CASE - NV243 (Continued)

(8) Install the drive sprocket retaining ring (Fig.
60) onto the output shaft.
(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 61). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(10) Install the shift sector o-ring.(11) Assemble and install range fork and hub (Fig.
62). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install the range fork retaining ring.
(14) Install mode fork and shift rail onto the mode
sleeve.
(15) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 63).
Fig. 63 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 60 Install The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 61 Install Shift Sector
1 - SHIFT SECTOR
Fig. 62 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
DRTRANSFER CASE - NV243 21 - 501
TRANSFER CASE - NV243 (Continued)

(4) Position the shift motor and mode sensor
assembly onto the transfer case.
(5) Install the bolts 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.).
REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) 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.
(3) Align and install rear extension on retainer
(Fig. 76).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 ft. lbs.) torque.
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 - NV243
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 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-24 12-18 -
Fig. 76 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
DRTRANSFER CASE - NV243 21 - 505
TRANSFER CASE - NV243 (Continued)

EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Using Installer D-163, install seal in extension
housing (Fig. 77).
(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. 78).
(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 20-34 N´m
(15-25 ft. lbs.).
(5) Remove drain pan.
(6)
Fill transfer case to bottom edge of fill plug open-
ing with MopartATF +4, Automatic Transmission fluid.
(7) Install and tighten fill plug to 20-34 N´m
(15-25 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) Remove the front propeller shaft seal boot
retaining clamp (Fig. 79).
Fig. 79 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 77 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
Fig. 78 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV243 21 - 507

IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID 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
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range sleeve.
The front output shaft is operated by a drive chain
that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is splined to a differ-
ential assembly. Depending on the position of the
mode fork and sleeve, the front output shaft is driven
directly by the mainshaft or through the differential.
The mode fork operates the mode sleeve and hub.
The sleeve and hub are not equipped with a synchro-
nizer mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV244
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) Insufficient or incorrect lubricant. 2) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, Automatic Transmission Fluid.
3) Internal transfer case
components binding, worn, or
damaged.3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, Automatic Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Transfer case noisy while in, or
jumps out of, 4LO.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or the
clutch depressed on vehicles
equipped with a manual
transmission, shift the transfer case
to the AWD or 4HI position, and
then back into the 4LO position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV244 GENII 21 - 513
TRANSFER CASE - NV244 GENII (Continued)

(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 45).
(9) Remove the rear output shaft bearing from the
rear case using Installer 5065 and Handle C-4171
(Fig. 46).
(10) Install the rear output shaft bearing (Fig. 47)
into the rear case using Remover/Installer 6953 and
Handle C-4171.
INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 48)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 48). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
Fig. 45 Front Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 46 Remove Rear Output Shaft Bearing
1 - HANDLE C-4171
2 - INSTALLER 5065
Fig. 47 Install Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 6953
3 - HANDLE C-4171
Fig. 48 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
21 - 526 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 49). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 50).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
NOTE: Replace the mode hub retainer if the legs
were distorted during removal.
(2) Install the mode hub retainer (Fig. 51) onto the
mode hub.
(3) Install the mode hub (Fig. 52) and mode hub
retainer onto the differential assembly. Make sure
the retainer is fully seated onto the differential.
Fig. 49 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 50 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 51 Install Retainer onto Mode Hub
1 - MODE HUB RETAINER
2 - MODE HUB
Fig. 52 Install the Mode Hub and Retainer
1 - DIFFERENTIAL ASSEMBLY
2 - MODE HUB AND RETAINER
DRTRANSFER CASE - NV244 GENII 21 - 527
TRANSFER CASE - NV244 GENII (Continued)

(8) Install clutch shaft snap-ring (Fig. 57).
(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 58). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(10) Install the shift sector o-ring.(11) Assemble and install range fork and hub (Fig.
59). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install the shift rail (Fig. 60) into the range
fork assembly and the front case.
Fig. 57 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 58 Install Shift Sector
1 - SHIFT SECTOR
Fig. 59 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 60 Install Shift Rail
1 - SHIFT RAIL
2 - RANGE FORK ASSEMBLY
DRTRANSFER CASE - NV244 GENII 21 - 529
TRANSFER CASE - NV244 GENII (Continued)

SEAL BOOT AND SHIFT MOTOR ASSEMBLY
(1) Install a new seal boot clamp onto the seal
boot.
(2) Install the seal boot (Fig. 76) and clamp onto
the slinger hub and tighten the clamp with Crimp
Tool C-4975-A.
(3) Position the shift motor and mode sensor
assembly onto the transfer case.
(4) Install the bolts (Fig. 77) 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.).
REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171. Verify that
the weep hole in the rubber is oriented downward.
(2) 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.
(3) Align and install rear extension on retainer
(Fig. 78).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 ft. lbs.) torque.
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.
Fig. 76 Install Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 77 Install the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
Fig. 78 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 534 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)