boot DODGE RAM 2003 Service Manual PDF

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.
(6) Using a suitable pry tool (Fig. 7), remove the
slinger from the output shaft using care not to dam-
age the shaft.
Fig. 4 Remove Boot Clamp - Typical
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 3 Remove the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
Fig. 5 Remove Seal Boot - Typical
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears - Typical
1 - SLINGER
2 - BEND UPWARD
Fig. 7 Remove Slinger From Shaft - Typical
1 - SLINGER
2-PRYTOOL
DRTRANSFER CASE - NV243 21 - 661
TRANSFER CASE - NV243 (Continued)

(9) Install spring and cup on shift rail (Fig. 71).
(10) Insert magnet in front case pocket (Fig. 72).
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.
(4) Position the shift motor and mode sensor
assembly onto the transfer case.
(5) Install the bolts to hold the shift motor and
mode sensor assembly to the transfer case. Tighten
the bolts to 16-25 N´m (12-18 ft. lbs.).
REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
Fig. 71 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 72 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 73 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
21 - 678 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

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).
(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. 79 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
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
DRTRANSFER CASE - NV243 21 - 683

TRANSFER CASE - NV273
TABLE OF CONTENTS
page page
TRANSFER CASE - NV273
DESCRIPTION........................687
OPERATION..........................688
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV273.......................688
REMOVAL............................689
DISASSEMBLY........................689
CLEANING...........................698
INSPECTION.........................699
ASSEMBLY...........................701
INSTALLATION........................713
SPECIFICATIONS
TRANSFER CASE - NV273.............713
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........714
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................716
INSTALLATION........................716FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................716
FRONT OUTPUT SHAFT SEAL
REMOVAL............................717
INSTALLATION........................717
MODE SENSOR
DESCRIPTION........................718
OPERATION..........................718
SELECTOR SWITCH
DESCRIPTION........................719
OPERATION..........................719
SHIFT MOTOR
DESCRIPTION........................720
OPERATION..........................720
REMOVAL............................720
INSTALLATION........................720
TRANSFER CASE - NV273
DESCRIPTION
The NV273 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV273 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum case halves.
OPERATING RANGES
Transfer case operating ranges are:
²2WD (2-wheel drive)
²4HI (4-wheel drive)
²4LO (4-wheel drive low range)
²NEUTRAL
The 2WD range is for use on any road surface at
any time.The 4HI 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 wet or slip-
pery or 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
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 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.
DRTRANSFER CASE - NV273 21 - 687

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.
(7) Remove rear extension bolts (Fig. 5).
Fig. 3 Remove Companion Flange Nut - Typical
1 - HOLDER 6719
2 - BOLTS
Fig. 4 Remove Extension Housing Dust Boot
1 - EXTENSION HOUSING
2 - DUST BOOT
Fig. 5 Remove Extension Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
21 - 690 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(2) Engage the oil pump pick-up tube (Fig. 84) 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. 85) onto the
rear case half.(5) Install rear extension bolts (Fig. 86). Tighten
the bolts to 27-34 N´m (20-25 ft.lbs.).
(6) Install the extension housing dust boot and
seal assembly with Installer 9037 and Handle C-4171
(Fig. 87).
Fig. 84 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
Fig. 85 Install Extension Housing
1 - REAR CASE HALF
2 - EXTENSION HOUSING
Fig. 86 Install Extension Housing Bolts
1 - EXTENSION HOUSING
2 - BOLTS
Fig. 87 Install Extension Housing Seal
1 - EXTENSION HOUSING
2 - HANDLE C-4171
3 - INSTALLER 9037
21 - 712 TRANSFER CASE - NV273DR
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
21 - 716 TRANSFER CASE - NV273DR

INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION.............................63
4WD FLOOR SHIFT BOOT
REMOVAL.............................63
INSTALLATION.........................64
A-PILLAR TRIM/GRAB HANDLE
REMOVAL.............................64
INSTALLATION.........................64
B-PILLAR LOWER TRIM
REMOVAL.............................64
INSTALLATION.........................65
B-PILLAR UPPER TRIM
REMOVAL.............................65
INSTALLATION.........................65
CARPETS AND FLOOR MATS
REMOVAL.............................66
INSTALLATION.........................66
COAT HOOK
REMOVAL.............................67
INSTALLATION.........................67
COWL TRIM
REMOVAL.............................67
INSTALLATION.........................67
C-PILLAR LOWER TRIM
REMOVAL.............................67
INSTALLATION.........................68
C-PILLAR UPPER TRIM
REMOVAL.............................68
INSTALLATION.........................68
FLOOR CONSOLE
REMOVAL.............................68
INSTALLATION.........................68
HEADLINER
REMOVAL.............................69INSTALLATION.........................69
B-PILLAR GRAB HANDLE
REMOVAL.............................69
INSTALLATION.........................69
REAR CAB BACK PANEL TRIM
REMOVAL.............................70
INSTALLATION.........................70
REAR VIEW MIRROR
REMOVAL.............................71
INSTALLATION
INSTALLATION.......................71
INSTALLATION - REARVIEW MIRROR
SUPPORT BRACKET...................71
SUN VISOR
REMOVAL.............................71
INSTALLATION.........................71
SUN VISOR SUPPORT
REMOVAL.............................72
INSTALLATION.........................72
BODY VENT
REMOVAL.............................72
INSTALLATION.........................72
REAR DOOR SILL TRIM COVER
REMOVAL.............................72
INSTALLATION.........................72
LOAD FLOOR
REMOVAL.............................73
INSTALLATION.........................73
LOAD FLOOR SUPPORT CYLINDER
REMOVAL.............................73
INSTALLATION.........................73
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
4WD FLOOR SHIFT BOOT
REMOVAL
(1) Using a small pry bar or equivalent, remove
the insert, the nut and remove the shifter knob. (Fig.
2)
(2) Using a trim stick C-4755 or equivalent, pry up
the boot from the console. (Fig. 1)
DRINTERIOR 23 - 63

INSTALLATION
(1) Position the shift boot over the shifter lever
fully seat onto the console.
(2) Install the shifter knob and nut and tighten to
27 N´m (20 ft. lbs.).
(3) Position the insert and seat into the knob fully.
A-PILLAR TRIM/GRAB HANDLE
REMOVAL
(1) Open the trim plugs and remove the bolts. (Fig.
3)
(2) Remove the a-pillar trim/grab handle from the
a-pillar.
INSTALLATION
(1) Position the bottom a-pillar locating tabs and
install the a-pillar trim.
(2) Install the bolts and tighten to 6 N´m (55 in.
lbs.).
(3) Close the trim plugs.
B-PILLAR LOWER TRIM
REMOVAL
(1) Remove the upper b-pillar trim. (Refer to 23 -
BODY/INTERIOR/B-PILLAR UPPER TRIM -
REMOVAL)
(2) Remove the cowl trim. (Refer to 23 - BODY/IN-
TERIOR/COWL TRIM - REMOVAL)
STANDARD CAB
(1) Remove the shoulder belt anchor bolt.
(2) Using a trim stick C-4755 or equivalent,
remove the lower b-pillar trim. (Fig. 4)
QUAD CAB
(1) Remove the rear door sill trim. (Refer to 23 -
BODY/INTERIOR/REAR DOOR SILL TRIM COVER
- REMOVAL)
(2) Using a trim stick C-4755 or equivalent,
remove the lower b-pillar trim.
Fig. 1 SHIFTER BOOT
1 - CONSOLE
2 - SHIFTER KNOB
3 - SHIFTER BOOT
Fig. 2 SHIFTER KNOB
1 - SHIFTER KNOB
2 - INSERT
3 - NUT
Fig. 3 A-PILLAR TRIM/GRAB HANDLE
1 - A-PILLAR
2 - A-PILLAR TRIM
3 - TRIM PLUG
4 - BOLTS (2)
23 - 64 INTERIORDR
4WD FLOOR SHIFT BOOT (Continued)

INSTALLATION
(1) Route the shoulder belt through the slot in the
trim.
(2) Position the trim and seat the attachment clips
fully.
(3) Install the seat belt anchor bolt and tighten to
40 N´m (30 ft. lbs.).
(4) Install the upper c-pillar trim. (Refer to 23 -
BODY/INTERIOR/C-PILLAR UPPER TRIM -
INSTALLATION)
C-PILLAR UPPER TRIM
REMOVAL
(1) Remove the seat belt turning loop. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT TURNING
LOOP ADJUSTER - REMOVAL)
(2) Using a trim stick C-4755 or equivalent,
remove the upper c-pillar trim. (Fig. 11)
INSTALLATION
(1) Position the upper c-pillar trim and seat the
attachment clips fully.
(2) Install the seat belt turning loop. (Refer to 8 -
ELECTRICAL/RESTRAINTS/SEAT BELT TURNING
LOOP ADJUSTER - INSTALLATION)
FLOOR CONSOLE
REMOVAL
(1) Remove the 4WD shifter boot. (Refer to 23 -
BODY/INTERIOR/4WD FLOOR SHIFT BOOT -
REMOVAL)
(2) Using a trim stick C-4755 or equivalent, pry up
the transmission shifter boot from the console.
(3) Remove the transmission shifter extension.
(4) Remove the console inserts. (Fig. 12)
(5) Remove and discard the three bolts. (Fig. 13)
(6) Lift up on the back and remove the console.
INSTALLATION
(1) Position the front of the console up under the
instrument panel.
(2) Lower the back of the console and install three
new screws.
(3) Install the inserts.
(4) Install the transmission shifter extension.
(5) Position the transmission shifter boot in place
and seat the attachment clips fully.
(6) Install the 4WD shifter boot. (Refer to 23 -
BODY/INTERIOR/4WD FLOOR SHIFT BOOT -
INSTALLATION)
Fig. 12 FLOOR CONSOLE INSERTS
1 - BIN PAD INSERT
2 - STORAGE BIN/SHIFT BOOT
3 - CUP HOLDER INSERT
4 - FLOOR CONSOLE
Fig. 13 FLOOR CONSOLE
1 - INSTRUMENT PANEL
2 - FLOOR CONSOLE
3 - BOLTS (3)
4 - SHIFTER LEVER
23 - 68 INTERIORDR
C-PILLAR LOWER TRIM (Continued)