Transfer case DODGE RAM 1500 1998 2.G Workshop Manual

(2) Remove the shift motor and mode sensor
assembly from the transfer case.
(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 away from the transfer
case.
(6) Using a suitable pry tool, remove the slinger
from the output shaft using care not to damage the
shaft.
(7) Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
(1) Remove rear extension bolts (Fig. 7).
Fig. 7 Remove Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
Fig. 4 Remove Boot Clamp
1 - SEAL BOOT
2 - CLAMP
Fig. 5 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Upward
1 - SEAL SLINGER
2 - BEND UPWARD
DRTRANSFER CASE - NV244 GENII 21 - 515
TRANSFER CASE - NV244 GENII (Continued)

(2) Remove rear extension housing (Fig. 8). 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. 9).
OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bolts (Fig. 10).
(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 11).
(3) Unseat rear case from alignment dowels.
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.
Fig. 8 Remove Rear Extension
1 - EXTENSION HOUSING
2 - TRANSFER CASE
3 - PRY SLOT
Fig. 9 Remove Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 10 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 11 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
21 - 516 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove rear case and oil pump assembly from
front case (Fig. 12).
(5) Remove the oil pump pickup tube.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail spring (Fig. 13).(2) Remove front sprocket retaining ring (Fig. 14).
(3) Remove the mode fork (Fig. 15) and sleeve
from the shift rail and mainshaft.
Fig. 12 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 13 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 14 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 15 Remove Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
DRTRANSFER CASE - NV244 GENII 21 - 517
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove the rear output shaft retaining ring
(Fig. 16) from the output shaft.
(5) Pull front sprocket, rear sprocket, and chain
outward simultaneously (Fig. 17).
(6) Remove front sprocket, rear sprocket, and
chain as an assembly.
SHIFT FORKS AND MAINSHAFT
(1) Loosen detent plug.
(2) Remove detent plug, spring, and plunger (Fig.
18). Note that the plug has an O-ring seal. Remove
and discard this seal.
(3) Remove the front output shaft snap-ring (Fig.
19).
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
Fig. 16 Remove Rear Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - RETAINING RING
Fig. 17 Remove Drive Sprockets and Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
21 - 518 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove front output shaft from bearing in
case.
(5) Remove the mainshaft and differential assem-
bly (Fig. 20) from the input gear and transfer case.
(6) Remove the shift rail (Fig. 21) from the range
fork assembly and the front case.(7) Remove range fork and hub as an assembly
(Fig. 22). Note fork position for installation reference.
(8) Remove shift sector (Fig. 23).
Fig. 20 Remove Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 21 Remove Shift Rail
1 - SHIFT RAIL
2 - RANGE FORK ASSEMBLY
Fig. 22 Remove Range Fork and Sleeve
1 - RANGE SLEEVE
2 - RANGE FORK
Fig. 23 Shift Sector Removal
1 - SHIFT SECTOR
DRTRANSFER CASE - NV244 GENII 21 - 519
TRANSFER CASE - NV244 GENII (Continued)

(9) Remove the shift sector o-ring (Fig. 24).
MAINSHAFT
(1) Remove intermediate clutch shaft snap-ring
(Fig. 25).(2) Remove the intermediate clutch shaft thrust
ring (Fig. 26).
(3) Remove the intermediate clutch shaft (Fig. 27).
Fig. 24 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 25 Remove the Intermediate Clutch Shaft
Snap-ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 26 Remove the Intermediate Clutch Shaft
Thrust Ring
1 - CLUTCH SHAFT THRUST RING
Fig. 27 Remove the Intermediate Clutch Shaft
1 - INTERMEDIATE CLUTCH SHAFT
21 - 520 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove the differential snap-ring (Fig. 28).(5) Remove the differential assembly (Fig. 29) from
the mainshaft.
(6) Remove the mode hub (Fig. 30) and mode hub
retainer from the differential assembly.
(7) Remove the mode hub retainer (Fig. 31) from
the mode hub.
Fig. 28 Remove the Differential Snap-ring
1 - DIFFERENTIAL SNAP-RING
Fig. 29 Remove the Differential
1 - DIFFERENTIAL ASSEMBLY
2 - MAINSHAFT
Fig. 30 Remove the Mode Hub and Retainer
1 - DIFFERENTIAL ASSEMBLY
2 - MODE HUB AND RETAINER
Fig. 31 Remove Retainer from Mode Hub
1 - MODE HUB RETAINER
2 - MODE HUB
DRTRANSFER CASE - NV244 GENII 21 - 521
TRANSFER CASE - NV244 GENII (Continued)

INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 32) 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. 33). 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. 34).
(2) Remove retainer (Fig. 35).
Fig. 32 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 33 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 34 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 35 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
21 - 522 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(3) Remove front tabbed thrust washer (Fig. 36).
(4) Remove input gear (Fig. 37).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 38).
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 INSPECTION
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.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 39). 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. Minor nicks on the shift rail can be
smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 40). The
mode and range fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
Fig. 36 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 37 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 38 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
DRTRANSFER CASE - NV244 GENII 21 - 523
TRANSFER CASE - NV244 GENII (Continued)

REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing.
Replace both components if either show any sign of
wear or damage.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft splines and bearing surfaces.
Minor nicks on the splines can be smoothed with an
oilstone. Use 320-400 grit emery to smooth minor
scratches on the shaft bearing surfaces. Replace the
shaft if the bearing surfaces are scored or if any of
the splines are cracked or broken.Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 41)
Fig. 39 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. 40 Shift Fork and Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 41 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 524 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)