DODGE RAM 1500 1998 2.G Workshop Manual

(4) Install the differential assembly (Fig. 53) onto
the mainshaft.
(5) Install the differential snap-ring (Fig. 54).(6) Install the intermediate clutch shaft (Fig. 55).
(7) Install the clutch shaft thrust ring (Fig. 56).
Fig. 53 Install the Differential
1 - DIFFERENTIAL ASSEMBLY
2 - MAINSHAFT
Fig. 54 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 55 Installing Intermediate Clutch Shaft
1 - INTERMEDIATE CLUTCH SHAFT
Fig. 56 Installing Clutch Shaft Thrust Ring
1 - CLUTCH SHAFT THRUST RING
21 - 528 TRANSFER CASE - NV244 GENIIDR
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)

(14) Install the mainshaft and differential assem-
bly (Fig. 61) into the input gear and transfer case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft into the front out-
put shaft bearing.
(2) Install the front output shaft snap-ring (Fig.
62) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A(4) Install new o-ring on detent plug (Fig. 63).
NOTE: Shift the transfer case to the same range/
mode position it was in when the shift motor was
removed prior to installing the shift detent compo-
nents.
(5) Install detent plunger, spring, and plug (Fig.
64). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
Fig. 61 Install Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 62 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
Fig. 63 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 64 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
21 - 530 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(6) Install the new front output shaft seal slinger
(Fig. 65) with Installer 8840. Install the slinger onto
the shaft until the tool contacts the front of the out-
put shaft.
(7) Install the front sprocket, rear sprocket, and
chain as an assembly.
(8) Lower the front sprocket, rear sprocket, and
chain over the front and rear output shafts simulta-
neously (Fig. 66) until fully seated on both splines.(9) Install the rear output shaft retaining ring
(Fig. 67) onto the output shaft.
(10) Install the front sprocket retaining ring (Fig.
68).
Fig. 65 Install Front Output Shaft Seal Slinger
1 - SEAL SLINGER
2 - INSTALLER 8840
Fig. 66 Install Drive Sprockets and Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
Fig. 67 Install Rear Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - RETAINING RING
Fig. 68 Installing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
DRTRANSFER CASE - NV244 GENII 21 - 531
TRANSFER CASE - NV244 GENII (Continued)

(11) Inspect mode fork assembly (Fig. 69). Replace
pads if necessary. Also check springs and slider
bracket. Replace worn or damaged components.(12) Install the mode fork (Fig. 70) and sleeve over
the shift rail and mainshaft.
(13) Install spring onto the shift rail (Fig. 71).
(14) Insert magnet in front case pocket (Fig. 72).
Fig. 69 Mode Fork Assembly
1 - MODE FORK
2 - SPRING
Fig. 70 Install Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 71 Install Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 72 Install the Transfer Case Sump Magnet
1 - SUMP MAGNET
2 - CASE POCKET
21 - 532 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

OIL PUMP AND REAR CASE
Lubricate the oil pump components with transmis-
sion fluid before installation. Prime the oil pickup
tube by pouring a little oil into the tube before instal-
lation.
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 inner bear-
ing 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.
(1) Install new o-ring in pickup tube inlet of oil
pump, if necessary.
(2) Insert oil pickup tube into the oil pump.
(3) 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.
(4) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 73).
(5) Install rear output bearing snap-ring (Fig. 74)
to output shaft.
(6) Install 4-5 rear case-to front case bolts (Fig. 75)
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.(7) Apply MopartLock 'n Seal Adhesive to remain-
der of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 N´m (18-21 ft. lbs.),
Fig. 73 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 74 Install Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 75 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
DRTRANSFER CASE - NV244 GENII 21 - 533
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)

SPECIFICATIONS
TRANSFER CASE - NV244 GENII
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 25-28 18-21 -
Screw, Oil Pump 14-19 10-14 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-24 12-18 -
SPECIAL TOOLS
TRANSFER CASE - NV244 GENII
Handle, Universal - C-4171
Installer, Seal - D-163
Remover - L-4454
Installer, Seal - MB991168A
Installer, Bushing - 5065
DRTRANSFER CASE - NV244 GENII 21 - 535
TRANSFER CASE - NV244 GENII (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. 79).
(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.
Installer, Bushing - 5066
Installer, Bearing - 6953
Cup - 8148
Installer - 8840
Installer, Seal - 8841
Fig. 79 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 536 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 80).
(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
opening with MopartATF +4, Automatic Transmis-
sion 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. 81).
(3) Remove the front propeller shaft seal boot (Fig.
82).
Fig. 80 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 81 Remove Boot Clamp
1 - SEAL BOOT
2 - CLAMP
Fig. 82 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
DRTRANSFER CASE - NV244 GENII 21 - 537