Transfer case installation DODGE RAM 1500 1998 2.G Service Manual

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)

(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)

OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm  0.5mm
2 - POSITION 2 - 12mm  0.5mm
3 - POSITION 3 - 14mm  0.5mm
4 - POSITION 4 - 16mm  0.5mm
5 - POSITION 5 - 18mm  0.5mm
6 - POSITION 6 - 20mm 0.5mm - FULL EXTENSION
DRTRANSFER CASE - NV241 GENII 21 - 443
POSITION SENSOR (Continued)

INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 89).
(2) Position shift lever in vehicle.
(3) Install the bolts to hold the shifter mechanism
to the floor pan.
(4) Raise vehicle.
(5) Verify that the transfer case is still in the 2H
position. The 2H detent position on the transfer case
shift arm is the second position from full forward.
(6) Install trunnion to shift lever, if necessary.
(7) Install shift rod to trunnion, if necessary.(8) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(9) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(10) Lower vehicle.
(11) Install the transfer case shifter console.
(12) Install the shifter boot and the shifter knob
onto the shifter lever.
(13) Install nut to hold shifter knob to shift lever.
(14) Install shifter knob cap.
(15) Verify transfer case operation.
Fig. 89 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV241 GENII 21 - 445
SHIFT LEVER (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

(10) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 25).
(11) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 26). Note which way the sleeve fits
in the fork (long side of sleeve goes to front or the
points on the sleeve teeth go to the rear of case).(12) Remove range fork and hub as an assembly
(Fig. 27). Note fork position for installation reference.
(13) Remove shift sector (Fig. 28).
Fig. 25 Remove Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 26 Remove Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 27 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 28 Remove Shift Sector
1 - SHIFT SECTOR
21 - 456 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(12) Install new bearing with Tool Handle C-4171
and Installer 8128 (Fig. 50). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 51).(13) Remove seal from oil pump with suitable pry
tool.
(14) Install new seal in oil pump with Installer
7888 (Fig. 52).
(15) Remove the rear output shaft bearing snap-
ring (Fig. 53) from the rear case half.
Fig. 53 Remove Rear Output Bearing Outer
Snap-Ring
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT BEARING
3 - SNAP-RING
Fig. 50 Install Front Output Shaft Rear Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8128
Fig. 51 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 52 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
DRTRANSFER CASE - NV271 21 - 463
TRANSFER CASE - NV271 (Continued)

(12) Install mainshaft into the transfer case (Fig.
70). Guide mainshaft through the mode and range
sleeves and into the input gear.
(13) Install the transfer case position sensor (Fig.
71). Tighten the sensor to 20-34 N´m (15-25 ft. lbs.)
torque.(14) Install manual shift lever and spacer onto sec-
tor shaft (Fig. 72).
(15) 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.
(16) Install new o-ring on detent plug (Fig. 73).
Fig. 73 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 71 Install Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
Fig. 72 Install Manual Shift Lever
1 - SHIFT SECTOR
2 - SECTOR SUPPORT
3 - MANUAL SHIFT LEVER
21 - 468 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(8) Install front sprocket retaining ring (Fig. 78).
(9) Install rear sprocket retaining ring (Fig. 79).
(10) Install spring onto shift rail (Fig. 80).
(11) Insert magnet in front case pocket (Fig. 81).
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 he rear output shaft
bearing and align shift rail with bore in rear case.
Then install rear case (Fig. 82). Verify that the case
alignment dowels correctly seat into their mating
recesses.
(4) Install 4-5 rear case-to front case bolts (Fig. 83)
to hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
Fig. 78 Install Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 79 Install Rear Output Shaft Sprocket Retaining
Ring
1 - REAR OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 80 Install Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 81 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
21 - 470 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)