DODGE RAM 1500 1998 2.G Workshop Manual
Manufacturer: DODGE, Model Year: 1998, Model line: RAM 1500, Model: DODGE RAM 1500 1998 2.GPages: 2627
Page 2121 of 2627

SHIFT LEVER AND FRONT OUTPUT SHAFT SEAL
(1) Shift transfer case into NEUTRAL.
(2) Remove nut that retains the shift lever to sec-
tor shaft. Then remove shift lever from shaft (Fig. 3).
(3) Remove the front propeller shaft seal boot
retaining clamp (Fig. 4).
(4) Remove the front propeller shaft seal boot (Fig.
5).
(5) Remove the front output shaft seal slinger by
bending (Fig. 6) the slinger ears away from the
transfer case.
(6) Using a suitable pry tool (Fig. 7), remove the
slinger from the output shaft using care not to dam-
age the shaft.
(7) Using a screw and a slide hammer, remove the
front output shaft seal.
Fig. 3 Remove Range Lever Nut
1 - RANGE LEVER
Fig. 4 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 5 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 7 Remove Slinger From Shaft
1 - SLINGER
2-PRYTOOL
21 - 418 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2122 of 2627

REAR EXTENSION
(1) Remove rear extension bolts (Fig. 8).
(2) Remove rear extension housing (Fig. 9). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 10).
OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bolts (Fig. 11).
Fig. 8 Remove Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
Fig. 9 Remove Rear Extension
1 - EXTENSION HOUSING
2 - TRANSFER CASE
3 - PRY SLOT
Fig. 10 Remove Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 11 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
DRTRANSFER CASE - NV241 GENII 21 - 419
TRANSFER CASE - NV241 GENII (Continued)
Page 2123 of 2627

(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 12).
(3) Unseat rear case from alignment dowels.
(4) Remove rear case and oil pump assembly from
front case (Fig. 13).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail cup and spring (Fig. 14).
(2) Remove front sprocket retaining ring (Fig. 15).
Fig. 12 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
Fig. 13 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
Fig. 15 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
21 - 420 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2124 of 2627

(3) Pull mainshaft, front sprocket and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
16).
(4) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as assembly.
SHIFT FORKS AND MAINSHAFT
(1) Remove the transfer case position sensor (Fig.
17).(2) Loosen detent plug.
(3) Remove detent plug, spring, and plunger (Fig.
18). Note that the plug has an O-ring seal. Remove
and discard this seal.
(4) Remove the front output shaft snap-ring (Fig.
19).
Fig. 16 Remove Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 17 Remove Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
Fig. 18 Remove Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 19 Remove Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
DRTRANSFER CASE - NV241 GENII 21 - 421
TRANSFER CASE - NV241 GENII (Continued)
Page 2125 of 2627

(5) Remove front output shaft from bearing in case
(Fig. 20).
(6) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 21).(7) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 22). Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
(8) Remove range fork retaining ring.
(9) Remove range fork and hub as an assembly
(Fig. 23). Note fork position for installation reference.
Fig. 23 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 21 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 22 Remove Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
21 - 422 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2126 of 2627

(10) Remove the shift sector support (Fig. 24).
(11) Remove shift sector (Fig. 25).MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
26) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
27) from the output shaft.
Fig. 24 Remove Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
Fig. 25 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 26 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 27 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
DRTRANSFER CASE - NV241 GENII 21 - 423
TRANSFER CASE - NV241 GENII (Continued)
Page 2127 of 2627

(3) Remove drive sprocket (Fig. 28) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 29) and hub (Fig.
30) from the output shaft.
(5) Remove the mode hub retaining ring (Fig. 31)
from the output shaft.
Fig. 31 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 28 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
21 - 424 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2128 of 2627

(6) Remove the mode hub (Fig. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 34). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 35).
Fig. 35 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 33 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 34 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
DRTRANSFER CASE - NV241 GENII 21 - 425
TRANSFER CASE - NV241 GENII (Continued)
Page 2129 of 2627

(2) Remove retainer (Fig. 36).
(3) Remove front tabbed thrust washer (Fig. 37).
(4) Remove input gear (Fig. 38).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 39).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3MŸ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone, however, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
Fig. 36 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 38 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 426 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2130 of 2627

INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 40). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 41). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 42). The
mode fork pads are serviceable and can be replaced if
necessary. The range fork pads are not serviceable.
The fork must be replaced as an assembly if the pads
are worn or damaged.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bear-
ing if rough or noisy. Check the retainer for cracks or
wear in the bearing bore.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended.
Inspect rear extension bushing. Replace if worn or
scored.
Fig. 40 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 41 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
DRTRANSFER CASE - NV241 GENII 21 - 427
TRANSFER CASE - NV241 GENII (Continued)