DODGE RAM 1500 1998 2.G Workshop Manual

(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)

SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Handle, Universal - C-4171
Remover - L-4454
Installer, Bearing - 6953
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8128
Cup - 8148
Installer - 8151
Installer - 8152
DRTRANSFER CASE - NV273 21 - 569
TRANSFER CASE - NV273 (Continued)

Installer - 8891
Socket - 9033
Installer, Bearing - 9035
Installer, Seal - 9036
Installer, Seal - 9037
21 - 570 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

have not been met. This is in an attempt to notify
the driver that the transmission needs to be put into
NEUTRAL, the vehicle speed is too great, or some
other condition outlined (other than a diagnostic fail-
ure that would prevent this shift) elsewhere (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/TRANSFER CASE CONTROL MODULE -
OPERATION) is not met. Note that this flashing will
continue indefinitely until the conditions are eventu-
ally met, or the selector switch position is changed,
or if diagnostic routines no longer allow the
requested shift.
²
If the driver attempts to make a shift into transfer
case NEUTRAL, and any of the driver controllable con-
ditions are not met, the request will be ignored until all
of the conditions are met or until the NEUTRAL select
button is released. Additionally the neutral lamp will
flash, or begin to flash while the button is depressed
and operator controllable conditions are not being met.
All of the LED's except the Neutral will flash if any of
the operator controllable conditions for shifting are not
met while the Neutral button is depressed. This9toggle9
type of feature is necessary because the TCCM would
interpret another request immediately after the shift
into transfer case NEUTRAL has completed.
²No LED's illuminated indicate a fault in the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shift motor (Fig. 96) consists of a permanent
magnet D.C. motor with gear reduction to convert a
high speed-low torque device into a low speed-high
torque device. The output of the device is coupled to
a shaft which internally moves the mode and range
forks that change the transfer case operating ranges.
The motor is rated at 25 amps maximum at 72É F
with 10 volts at the motor leads.
OPERATION
The transfer case shift motor responds to the
Transfer Case Control Module (TCCM) commands to
move the transfer case shift sector bi-directionally, as
required, to obtain the transfer case operating mode
indicated by the instrument panel mounted selector
switch.
REMOVAL
NOTE: New shift motor assemblies are shipped in
the 2WD/AWD position. If a new shift motor assem-
bly will be installed, it will be necessary to shift the
transfer case to the 2WD/AWD position prior to
motor removal.(1) Raise the vehicle on a suitable hoist.
(2) Disengage the wiring connectors from the shift
motor and mode sensor.
(3) Remove the bolts holding the shift motor and
mode sensor assembly onto the transfer case.
(4) Separate the shift motor and mode sensor
assembly from the transfer case.
INSTALLATION
(1) Verify that the shift sector o-ring is clean and
properly positioned over the shift sector and against
the transfer case.
NOTE: Verify that the shift motor position and sec-
tor shaft orientation are aligned. It may be neces-
sary to manually shift the transfer case if the shift
motor and sector shaft are not aligned.
(2) Position the shift motor and mode sensor
assembly onto the transfer case.
(3) Install the bolts to hold the assembly onto the
transfer case. Tighten the bolts to 16-24 N´m (12-18
ft.lbs.).
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
MoparTLock & Seal or LoctiteŸ 242 to replenish
the lock patch material originally found on the bolts
(4) Engage the wiring connectors to the shift motor
and mode sensor.
(5) Refill the transfer case as necessary.
(6) Lower vehicle and verify transfer case
operation.
Fig. 96 Shift Motor - Shown Inverted - Typical
1 - SHIFT MOTOR
DRTRANSFER CASE - NV273 21 - 575
SELECTOR SWITCH (Continued)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT......................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION . 3
STANDARD PROCEDURE - MATCH
MOUNTING...........................3
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................4
TIRES
DESCRIPTION
DESCRIPTION - SPARE TIRE /
TEMPORARY.........................6
DESCRIPTION - TIRES..................6
DESCRIPTION - RADIAL ± PLY TIRES......6
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEEDS.........................7
DESCRIPTION - REPLACEMENT TIRES.....7
DESCRIPTION - TIRE INFLATION
PRESSURES..........................7
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES.............................7
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION........................7
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS..........................8
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS...........................8
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD................................8STANDARD PROCEDURE - REPAIRING
LEAKS..............................10
SPECIFICATIONS
TIRE REVOLUTIONS PER MILE..........10
WHEELS
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING
WHEEL INSPECTION..................11
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
REPLACEMENT.......................12
STANDARD PROCEDURE - DUAL REAR
WHEEL INSTALLATION.................12
SPECIFICATIONS
TORQUE CHART......................13
STUDS
REMOVAL.............................14
INSTALLATION.........................14
WHEEL COVER
REMOVAL.............................14
INSTALLATION
INSTALLATION - REAR.................14
INSTALLATION - FRONT................14
SPARE TIRE
DESCRIPTION
DESCRIPTION - SPARE / TEMPORARY
TIRE...............................15
DESCRIPTION - FULL SIZE, SPARE WHEEL
WITH MATCHING TIRE.................15
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radial runout is the difference between the high
and low points on the tire or wheel (Fig. 1).
Lateral runout is thewobbleof the tire or wheel.
Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
DRTIRES/WHEELS 22 - 1