transfer DODGE RAM 1500 1998 2.G Workshop Manual

TRANSFER CASE - NV244 GENII
TABLE OF CONTENTS
page page
TRANSFER CASE - NV244 GENII
DESCRIPTION........................512
OPERATION..........................513
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV244.......................513
REMOVAL............................514
DISASSEMBLY........................514
CLEANING...........................523
INSPECTION.........................523
ASSEMBLY...........................525
INSTALLATION........................534
SPECIFICATIONS
TRANSFER CASE - NV244 GENII........535
SPECIAL TOOLS
TRANSFER CASE - NV244 GENII........535
EXTENSION HOUSING SEAL
REMOVAL............................536
INSTALLATION........................536FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................537
FRONT OUTPUT SHAFT SEAL
REMOVAL............................537
INSTALLATION........................538
MODE SENSOR
DESCRIPTION........................538
OPERATION..........................539
SELECTOR SWITCH
DESCRIPTION........................539
OPERATION..........................540
SHIFT MOTOR
DESCRIPTION........................541
OPERATION..........................541
REMOVAL............................541
INSTALLATION........................541
TRANSFER CASE - NV244
GENII
DESCRIPTION
The NV244 GENII is an electronically controlled
full and part-time transfer case with no two wheel
drive operation.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear reduction system provides increased low
speed torque capability for off road operation. The
low range provides a 2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
OPERATING RANGES
NV244 GENII operating ranges are:
²AWD(All-Wheel Drive)
²4HI (Part-time)
²4LO
²NEUTRAL
The AWD mode can be used at any time and on
any road surface.The 4HI (Part-time) and 4LO ranges are for off
road use only. The only time these ranges can be
used is when the road surface is covered with snow,
ice, or other loose slippery material.
SHIFT MECHANISM
Operating ranges are selected with a dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver's desire to
change operating ranges. The TCCM uses this input,
along with the input from the transfer case mounted
mode sensor and information from the vehicle's bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
21 - 512 TRANSFER CASE - NV244 GENIIDR

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)

CONDITION POSSIBLE CAUSE CORRECTION
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Transfer case will not shift through
4HI (Part-time) range.1) Incomplete shift due to drivetrain
torque load.1) Drive in a straight line and
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
REMOVAL
(1) Shift transfer case into AWD.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shafts for align-
ment reference.
(5) Support transmission with jack stand.
(6)
Remove the transfer case skid plate, if equipped.
(7) Disconnect front and rear propeller shafts at
transfer case.
(8) Disconnect transfer case shift motor and mode
sensor wire connectors.
(9) Disconnect transfer case vent hose.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission (Fig. 2).(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT
SHAFT SEAL
(1) Remove the bolts (Fig. 3) which hold the shift
motor and mode sensor assembly to the transfer
case.
Fig. 2 Remove Transfer Case - Typical
1 - TRANSMISSION
2 - TRANSFER CASE
3 - MODE SENSOR CONNECTOR
Fig. 3 Remove the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
21 - 514 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(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)