DODGE RAM 2003 Service Repair Manual

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.
63) onto the mainshaft.(3) Install the mode hub (Fig. 64) onto the main-
shaft.
(4) Install the mode hub retaining ring (Fig. 65)
onto the mainshaft.
(5) Install the clutch gear (Fig. 66) onto the output
shaft. Verify that the pointed ends of the clutch gear
teeth are pointing to the front of the mainshaft.
Fig. 64 Install Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 63 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 65 Install Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
Fig. 66 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
21 - 642 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(6) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 67). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(7) Apply LoctiteŸ 242, or equivalent, to the
threads of the sector support to replentish the factory
applied patch. Install the shift sector support.
Tighten the sector support with Socket 9033 to 27-34
N´m (20-25 ft.lbs.).
(8) Assemble and install range fork and hub (Fig.
68). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(9) Align and insert range fork pin in shift sector
slot.
(10) Install mode fork and shift rail onto the mode
sleeve.(11) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 69).
(12) Install mainshaft into the transfer case (Fig.
70). Guide mainshaft through the mode and range
sleeves and into the input gear.
Fig. 67 Install Shift Sector
1 - SHIFT SECTOR
Fig. 68 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 69 Install Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 70 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
DRTRANSFER CASE - NV271 21 - 643
TRANSFER CASE - NV271 (Continued)

(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).
(17) Install detent plunger, spring, and plug (Fig.
74). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
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
Fig. 73 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 74 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
21 - 644 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 75) into the
front output shaft front bearing.
(2) Install the front output shaft bearing inner
snap-ring (Fig. 76) 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. 77) over the
output shaft and lower the sprocket and chainassembly 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.
(8) Install front sprocket retaining ring (Fig. 78).
Fig. 78 Install Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 75 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 76 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 77 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
DRTRANSFER CASE - NV271 21 - 645
TRANSFER CASE - NV271 (Continued)

(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 sealerbead 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.
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.
(5) Tighten bolts to 27-34 N´m (20-25 ft. lbs.),
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
Fig. 82 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
21 - 646 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(6) Install rear output bearing inner snap-ring
(Fig. 84) to output shaft.OIL PUMP AND REAR EXTENSION
(1) Install the oil pump (Fig. 85) onto the output
shaft.
(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.
Fig. 83 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 84 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 85 Install Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
Fig. 86 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
DRTRANSFER CASE - NV271 21 - 647
TRANSFER CASE - NV271 (Continued)

(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. 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 - 648 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
companion flange (Fig. 90).
(10) Install a new front companion flange nut.
Tighten the companion flange nut to 176-271 N´m
(130-200 ft.lbs.).
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 - NV271
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Fig. 90 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
DRTRANSFER CASE - NV271 21 - 649
TRANSFER CASE - NV271 (Continued)

SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Handle, Universal - C-4171
Remover - L-4454
Installer, Bearing - 6953
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8128
Cup - 8148
Installer - 8151
Installer - 8152
21 - 650 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

Installer - 8891
Socket - 9033
Installer, Bearing - 9035
Installer, Seal - 9036
Installer, Seal - 9037
DRTRANSFER CASE - NV271 21 - 651
TRANSFER CASE - NV271 (Continued)