Drive shaft DODGE RAM 1500 1998 2.G Workshop Manual

(3) Remove the mode hub (Fig. 30) from the main-
shaft.
(4) Remove the drive sprocket drive hub (Fig. 31)
from the mainshaft.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.
Fig. 30 Remove Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 31 Remove the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
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
21 - 552 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 40). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 41). 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.
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 threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320-400 grit emery to
smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth 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. 42)
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Fig. 40 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
Fig. 41 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 42 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
DRTRANSFER CASE - NV273 21 - 555
TRANSFER CASE - NV273 (Continued)

(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 61).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.
(9) Install a new input gear oil seal with Installer
9036 and Handle C-4171.
SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (Fig.
62) onto the mainshaft.(3) Install the mode hub (Fig. 63) onto the main-
shaft.
(4) Install the mode hub retaining ring (Fig. 64)
onto the mainshaft.
Fig. 61 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 62 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 63 Install Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 64 Install Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
DRTRANSFER CASE - NV273 21 - 561
TRANSFER CASE - NV273 (Continued)

(3) Install mainshaft into the transfer case (Fig.
73). Guide mainshaft through the mode and range
sleeves and into the input gear.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 74) into the
front output shaft front bearing.
(2) Install the front output shaft bearing inner
snap-ring (Fig. 75) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front drive sprocket in drive chain.
(5) Install drive chain around rear drive sprocket.(6) Position rear drive sprocket (Fig. 76) over the
output shaft and lower the sprocket and chain
assembly until the front sprocket is positioned over
the front output shaft.
(7) Align the splines in the sprockets to the splines
on the output shafts and install the sprockets onto
the output shafts.
Fig. 73 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 74 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 75 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 76 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
21 - 564 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(8) Install front sprocket retaining ring (Fig. 77).
(9) Install rear sprocket retaining ring (Fig. 78).(10) Insert magnet in front case pocket (Fig. 79).
REAR CASE
(1) Install the oil pick-up tube and screen into the
rear case half.
(2) 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.
(3) Align mainshaft with the rear output shaft
bearing and align shift rail with bore in rear case.
Then install rear case (Fig. 80). Verify that the case
alignment dowels correctly seat into their mating
recesses.
Fig. 77 Install Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 78 Install Rear Output Shaft Sprocket Retaining
Ring
1 - REAR OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 79 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 80 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
DRTRANSFER CASE - NV273 21 - 565
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)

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)

METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Drive vehicle a short distance to eliminate tire
flat spotting from a parked position.
(2) Check wheel bearings and adjust if adjustable
or replace if necessary.
(3) Check the wheel mounting surface.
(4) Relocate wheel on the mounting, two studs
over from the original position.
(5) Tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
(6) Check radial runout. If still excessive, mark
tire sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove tire from wheel and mount wheel on
service dynamic balance machine.
(2) Check wheel radial runout (Fig. 2) and lateral
runout (Fig. 3).
²STEEL WHEELS: Radial runout 0.031 in., Lat-
eral runout 0.031 in. (maximum)
²ALUMINUM WHEELS: Radial runout 0.020 in.,
Lateral runout 0.025 in. (maximum)
(3) If point of greatest wheel lateral runout is near
original chalk mark, remount tire 180 degrees.
Recheck runout, Refer to match mounting procedure.
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
22 - 2 TIRES/WHEELSDR
TIRES/WHEELS (Continued)

(2) Install the three nuts attaching the center seat
section to the other seat, and tighten to 25 N´m (18
ft. lbs.).
(3) Roll the seat assembly forward and install new
rear bolts.
(4) Connect the 12v power supply electrical con-
nector.
(5) Tighten the rear bolts to 40 N´m (30 ft. lbs.).
(6) Fold the seat backs up and slide the seats to
the rear.
(7) Install new front bolts and tighten to 28 N´m
(21 ft. lbs.).
LUMBAR SUPPORT HANDLE/
BEZEL
REMOVAL
CAUTION: Care must be taken not to damage the
handle or bezel surface when removing.
(1) Using a trim stick C-4755 or equivalent, pry
the manual lumbar knob out of the bezel surround.
(Fig. 15)
(2) Remove the bezel retaining screws and remove
the bezel. (Fig. 16)
INSTALLATION
(1) Align the bezel to the seat back and install the
screws.
(2) Snap the manual lumbar knob onto the shaft of
the drive mechanism into the bezel surround.
SEAT BACK CUSHION / COVER
- FRONT
REMOVAL
(1) Remove the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the lumbar handle and bezel, if
equipped. (Refer to 23 - BODY/SEATS/LUMBAR
SUPPORT HANDLE/BEZEL - REMOVAL)
(3) Remove the headrest sleeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - REMOVAL)
(4) Unzip the zip strip at the lower end of the seat
back and remove the seat back cover and cushion.
INSTALLATION
(1) Install the seat back cushion and cover onto
the seat frame assembly.
(2) Connect the zip strip at the bottom of the seat
back.
(3) Install the headrest sleeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - INSTALLA-
TION)
(4) Install the lumbar bezel and handle, if
equipped. (Refer to 23 - BODY/SEATS/LUMBAR
SUPPORT HANDLE/BEZEL - INSTALLATION)
(5) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - INSTALLATION)
Fig. 15 MANUAL LUMBAR KNOB
Fig. 16 MANUAL LUMBAR BEZEL
1 - LUMBAR SHAFT
2 - SCREWS
3 - BEZEL
23 - 82 SEATSDR
SEAT - FRONT (Continued)