boot DODGE RAM 1500 1998 2.G Repair Manual

REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.
(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move 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.
COMPANION FLANGE AND EXTENSION HOUSING
(1) Install two bolts 180É apart into the front out-
put shaft companion flange.
(2) Place holder over the bolts and against the
companion flange (Fig. 3).
(3) Remove and discard the front companion flange
nut.
(4) Remove the companion flange from the front
output shaft. It may be necessary to use Flange
puller 8992 to remove the companion flange.
(5) Use a suitable chisel or pry tool to remove the
rear extension housing dust boot (Fig. 4).
(6) Use a suitable chisel or pry tool to remove the
rear extension housing seal.
Fig. 3 Remove Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
Fig. 4 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
21 - 450 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(2) Engage the oil pump pick-up tube (Fig. 86) into
the oil pump. Verify that the pick-up tube o-ring is
on the tube and is correctly installed to the oil pump.
(3) 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.
(4) Install extension housing (Fig. 87) onto the
rear case half.(5) Install rear extension bolts (Fig. 88). Tighten
the bolts to 27-34 N´m (20-25 ft.lbs.).
(6) Install the extension housing boot and seal
assembly with Installer 9037 and Handle C-4171
(Fig. 89).
Fig. 86 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
Fig. 87 Install Extension Housing
1 - REAR CASE HALF
2 - EXTENSION HOUSING
Fig. 88 Install Extension Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
Fig. 89 Install Extension Housing Seal
1 - EXTENSION HOUSING
2 - HANDLE C-4171
3 - INSTALLER 9037
21 - 472 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (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. 91).
(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. 92).
(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. 93).
(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. 91 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
Fig. 92 Install Extension Housing Seal
1 - EXTENSION HOUSING
2 - HANDLE C-4171
3 - INSTALLER 9037
Fig. 93 Drain and Fill Locations
1 - FILL HOLE
2 - DRAIN HOLE
21 - 476 TRANSFER CASE - NV271DR

SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Raise and support the vehicle.
(3) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(4) Lower vehicle.
(5) Remove transfer case shifter knob cap.
(6) Remove nut holding shifter knob to shift lever.
(7) Remove shifter knob.
(8) Remove the shift boot from the shifter console.
(9) Remove the bolts securing the shifter mecha-
nism to the floor pan (Fig. 97).
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 97 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV271 21 - 479

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. 98).
(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. 98 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 480 TRANSFER CASE - NV271DR
SHIFT LEVER (Continued)

ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion.
(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion. Lubricate the shift rod
and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H
detent position. The 2H detent position on the trans-
fer case shift arm is the second position from full for-
ward.
(6) Align the adjustment locating hole on the lower
shifter lever with the adjustment channel on the
shifter bracket assembly (Fig. 99).(7) Insert an appropriately sized pin through into
the adjustment channel and through the locating
hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N´m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans-
fer case shifts into and operates properly in all
ranges.
Fig. 99 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV271 21 - 481
SHIFT LEVER (Continued)

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.
(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 ears away from the
transfer case.
Fig. 4 Remove Boot Clamp - Typical
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 5 Remove Seal Boot - Typical
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears - Typical
1 - SLINGER
2 - BEND UPWARD
Fig. 3 Remove the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
DRTRANSFER CASE - NV243 21 - 485
TRANSFER CASE - NV243 (Continued)

OIL PUMP AND REAR CASE
Lubricate the oil pump components with transmis-
sion fluid before installation. Prime the oil pickup
tube by pouring a little oil into the tube before instal-
lation.
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) Install new o-ring in pickup tube inlet of oil
pump.
(2) Insert oil pickup tube into the oil pump.
(3) 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.
(4) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 73).
(5) Install 4-5 rear case-to front case bolts (Fig. 74)
to hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts. Case
could be cracked if shaft rail or dowels are mis-
aligned.(6) Apply LoctiteŸ 242 to remainder of rear case-
to-front case bolt threads and install bolts. Tighten
bolts to 20-27 N´m (15-24 ft. lbs.),
(7) Install rear output bearing snap-ring (Fig. 75)
to output shaft.
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
(1) 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.
(2) Install a new seal boot clamp onto the seal
boot.
(3) Install the seal boot and clamp onto the slinger
hub and tighten the clamp with Crimp Tool
C-4975-A.
Fig. 73 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 74 Install Case Bolts - Typical
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 75 Install Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
21 - 504 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

EXTENSION HOUSING 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. 77).
(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. 78).
(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 open-
ing with MopartATF +4, Automatic Transmission 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. 79).
Fig. 79 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 77 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
Fig. 78 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV243 21 - 507

(3) Remove the front propeller shaft seal boot (Fig.
80).
(4) Remove the front output shaft seal slinger by
bending (Fig. 81) the slinger ears away from the
transfer case.
(5) Using a suitable pry tool (Fig. 82), 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).Fig. 80 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 81 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 82 Remove Slinger From Shaft
1 - SLINGER
2-PRYTOOL
21 - 508 TRANSFER CASE - NV243DR
FRONT OUTPUT SHAFT SEAL (Continued)