Drive shaft DODGE RAM 1500 1998 2.G Workshop Manual

SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install the mode hub (Fig. 55) onto the output
shaft.
(3) Install the mode hub retaining ring (Fig. 56)
onto the output shaft.
(4) Install the sprocket hub (Fig. 57) onto the out-
put shaft.
(5) Install the clutch gear (Fig. 58) onto the output
shaft.
(6) Install the drive sprocket (Fig. 59) onto the out-
put shaft.
Fig. 55 Install Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 56 Install Mode Hub Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 57 Install Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 58 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 59 Install Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
21 - 432 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(7) Install the drive sprocket thrust washer (Fig.
60) onto the output shaft.
(8) Install the drive sprocket retaining ring (Fig.
61) onto the output shaft.(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 62). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(10) Install the shift sector support (Fig. 63).
Tighten the sector support to 27-42 N´m (20-30
ft.lbs.).
Fig. 60 Install Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
Fig. 61 Install The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 62 Install Shift Sector
1 - SHIFT SECTOR
Fig. 63 Install Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
DRTRANSFER CASE - NV241 GENII 21 - 433
TRANSFER CASE - NV241 GENII (Continued)

(18) Install range lever on sector shaft (Fig. 68).
(19) Install washer and nut on sector shaft to
secure shift lever. Apply 1-2 drops MopartLock N'
Seal, or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N´m (20-25 ft. lbs.) torque.
(20) Install new o-ring on detent plug (Fig. 69).
(21) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 71) into the
front output shaft bearing.
(2) Install the front output shaft retaining ring
(Fig. 72) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front sprocket in drive chain.
Fig. 68 Install Range Lever Nut
1 - RANGE LEVER
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 71 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 72 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
DRTRANSFER CASE - NV241 GENII 21 - 435
TRANSFER CASE - NV241 GENII (Continued)

(5) Install drive chain around mainshaft sprocket
(Fig. 73). Then position front sprocket over front
shaft.
(6) Raise mainshaft about 2.54 cm (one inch) and
seat front sprocket on front output shaft.
(7) If mainshaft and mode sleeve were unseated
during chain installation, align and reseat mainshaft
in input gear and hub.
(8) Install front sprocket retaining ring (Fig. 74).(9) Install spring and cup on shift rail (Fig. 75).
(10) Insert magnet in front case pocket (Fig. 76).
OIL PUMP AND REAR CASE
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) 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.
Fig. 73 Install Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 74 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 75 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 76 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
21 - 436 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(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. 80).
(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) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.
(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 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 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 438 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

EXTENSION HOUSING
BUSHING AND 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. 81).
(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.
Plug, Extension - C-293-3
Remover - L-4454
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 81 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 440 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 82).
(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. 83).
(3) Remove the front propeller shaft seal boot (Fig.
84).
Fig. 83 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 84 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 82 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV241 GENII 21 - 441

(4) Remove the front output shaft seal slinger by
bending (Fig. 85) the slinger ears away from the
transfer case.
(5) Using a suitable pry tool (Fig. 86), remove the
slinger from the output shaft using care not to dam-
age the shaft.(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 output shaft seal slinger with
Installer 8840. Install the slinger onto the shaft until
the tool contacts the rear of the output shaft.
(3) Install a new seal boot clamp onto the seal
boot.
(4) Install the seal boot and clamp onto the slinger
hub and tighten the clamp with Crimp Tool
C-4975-A.
(5) Install front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION).
POSITION SENSOR
DESCRIPTION
The transfer case position sensor is an electronic
device whose output can be interpreted to indicate
the transfer case's current operating mode. The sen-
sor consists of a five position, resistive multiplexed
circuit which returns a specific resistance value to
the Powertrain Control Module (PCM) for each trans-
fer case operating mode. The sensor is located on the
top of the transfer case, just left of the transfer case
centerline and rides against the sector plate rooster-
comb. The PCM supplies 5VDC (+/- 0.5V) to the sen-
sor and monitors the return voltage to determine the
sector plate, and therefore the transfer case, position.
OPERATION
During normal vehicle operation, the Powertrain
Control Module (PCM) monitors the transfer case
position sensor return voltage to determine the oper-
ating mode of the transfer case. Refer to the Operat-
ing Mode Versus Resistance table for the correct
resistance for each position (Fig. 87).
Fig. 85 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 86 Remove Slinger From Shaft
1 - SLINGER
2-PRYTOOL
21 - 442 TRANSFER CASE - NV241 GENIIDR
FRONT OUTPUT SHAFT SEAL (Continued)

TRANSFER CASE - NV271
TABLE OF CONTENTS
page page
TRANSFER CASE - NV271
DESCRIPTION........................447
OPERATION..........................448
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV271.......................448
REMOVAL............................450
DISASSEMBLY........................450
CLEANING...........................459
INSPECTION.........................459
ASSEMBLY...........................461
INSTALLATION........................473
SPECIFICATIONS
TRANSFER CASE - NV271.............473
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........474
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................476INSTALLATION........................476
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................476
FRONT OUTPUT SHAFT SEAL
REMOVAL............................477
INSTALLATION........................477
POSITION SENSOR
DESCRIPTION........................477
OPERATION..........................477
REMOVAL............................478
INSTALLATION........................478
SHIFT LEVER
REMOVAL............................479
INSTALLATION........................480
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER..........481
TRANSFER CASE - NV271
DESCRIPTION
The NV271 transfer case is a part-time transfer
case with a low-range gear system. It provides three
operating ranges plus a NEUTRAL position. The low
range position provides a gear reduction ratio of
2.72:1 for increased low speed torque capability.
The gear cases and extension are all of aluminum
(Fig. 1). Drive sprockets and an interconnecting drive
chain are used to transmit engine torque to the front/
rear propeller shafts. The mainshaft, input gear and
front output shaft are supported by ball and needle
bearings.
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DRTRANSFER CASE - NV271 21 - 447

IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The 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
OPERATING RANGE
Transfer case operating ranges are:
²2H (2-wheel drive)
²4H (4-wheel drive)
²4LO (4-wheel drive low range
The 2H range is for use on any road surface at any
time.
The 4H and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is covered by
ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 448 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)