DODGE RAM 2003 Service Repair Manual

(7) Start front output shaft front bearing in case.
Then seat bearing with Installer 8891 (Fig. 46).
(8) Install front output shaft bearing retaining
ring.
(9) Remove input gear pilot bearing by inserting a
suitably sized drift into the splined end of the input
gear and driving the bearing out with the drift and a
hammer (Fig. 47).(10) Install new pilot bearing with Installer 9035.
(11) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 48).
(12) Install new bearing with Tool Handle C-4171
and Installer 8128 (Fig. 49). The bearing bore is
Fig. 47 Remove Input Gear Cup Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 48 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 49 Install Front Output Shaft Rear Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8128
Fig. 46 Install Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - INSTALLER 8891
21 - 702 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 50).
(13) Remove seal from oil pump with suitable pry
tool.
(14) Install new seal in oil pump with Installer
7888 (Fig. 51).
(15) Remove the rear output shaft bearing snap-
ring (Fig. 52) from the rear case half.
(16) Remove the rear output shaft bearing from
the rear case using Installer 7888 (Fig. 53).
Fig. 53 Remove Rear Output Shaft Bearing
1 - REAR CASE HALF
2 - INSTALLER 7888
Fig. 50 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 51 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
Fig. 52 Remove Rear Output Bearing Outer
Snap-Ring
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT BEARING
3 - SNAP-RING
DRTRANSFER CASE - NV273 21 - 703
TRANSFER CASE - NV273 (Continued)

(17) Install the rear output shaft bearing (Fig. 54)
into the rear case using Installer 8152 and Handle
C-4171.
(18) Install the rear output shaft bearing snap-
ring into the rear case half.
INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers with rec-
ommended transmission fluid.
(2) Install bottom thrust washer (Fig. 55) in low
range gear planetary. Be sure washer tabs are prop-
erly aligned in gear notches.
(3) Install input gear in low range gear (Fig. 56).
Be sure input gear is fully seated.
Fig. 54 Install Rear Output Shaft Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8152
Fig. 55 Install Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
Fig. 56 Install Input Gear From Planetary
1 - INPUT GEAR
2 - LOW RANGE PLANETARY
21 - 704 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(4) Install remaining thrust washer (Fig. 57) in
low range gear and on top of input gear.
(5) Install retainer (Fig. 58) on input gear and
install snap-ring (Fig. 59).
(6) Align and install low range/input gear assem-
bly in front case (Fig. 60). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
Fig. 59 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 60 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 57 Install Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 58 Install Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
DRTRANSFER CASE - NV273 21 - 705
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
21 - 706 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(5) Install the clutch gear (Fig. 65) onto the output
shaft. Verify that the pointed ends of the clutch gear
teeth are pointing to the front of the mainshaft.
(6) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 66). 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.
67). 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. 68).
Fig. 65 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 66 Install Shift Sector
1 - SHIFT SECTOR
Fig. 67 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 68 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
DRTRANSFER CASE - NV273 21 - 707
TRANSFER CASE - NV273 (Continued)

(12) Install new o-ring on detent plug (Fig. 69).
(13) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
(1) Position the shift motor and mode sensor
assembly (Fig. 71) onto the transfer case.
(2) Install the bolts (Fig. 72) 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.).
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
Fig. 71 Install Shift Motor Assembly Onto Transfer
Case
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
Fig. 72 Install Shift Motor Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
3 - BOLTS
21 - 708 TRANSFER CASE - NV273DR
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
DRTRANSFER CASE - NV273 21 - 709
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
21 - 710 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)

(4) Install 4-5 rear case-to front case bolts (Fig. 81)
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.),
(6) Install rear output bearing inner snap-ring
(Fig. 82) to output shaft.
OIL PUMP AND REAR EXTENSION
(1) Install the oil pump (Fig. 83) onto the output
shaft.
Fig. 83 Install Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
Fig. 81 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 82 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
DRTRANSFER CASE - NV273 21 - 711
TRANSFER CASE - NV273 (Continued)