torque DODGE RAM 2003 Service Repair Manual

SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 624 TRANSFER CASE - NV271DR
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)

(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)

(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)

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. 96).
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1172-1195
2 4H 677-691
3 NEUTRAL 406-415
4 4L 208-213
5 NOT USED 60-61
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. 96 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
21 - 654 TRANSFER CASE - NV271DR

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
2 - SHIFTER KNOB
3 - SHIFTER CONSOLE4 - SHIFTER MECHANISM
5 - ALIGNMENT PIN
6 - TRANSFER CASE
DRTRANSFER CASE - NV271 21 - 657
SHIFT LEVER (Continued)

TRANSFER CASE - NV243
TABLE OF CONTENTS
page page
TRANSFER CASE - NV243
DESCRIPTION........................658
OPERATION..........................659
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV243.......................659
REMOVAL............................660
DISASSEMBLY........................660
CLEANING...........................668
INSPECTION.........................668
ASSEMBLY...........................670
INSTALLATION........................679
SPECIFICATIONS
TRANSFER CASE - NV243.............680
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243........680
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL............................682
INSTALLATION........................682FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................682
FRONT OUTPUT SHAFT SEAL
REMOVAL............................683
INSTALLATION........................683
MODE SENSOR
DESCRIPTION........................684
OPERATION..........................684
SELECTOR SWITCH
DESCRIPTION........................685
OPERATION..........................685
SHIFT MOTOR
DESCRIPTION........................686
OPERATION..........................686
REMOVAL............................686
INSTALLATION........................686
TRANSFER CASE - NV243
DESCRIPTION
The NV243 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV243 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 retainer
housings bolted to the 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.
21 - 658 TRANSFER CASE - NV243DR

IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range sleeve.
The front output shaft is operated by a drive chain
that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is engaged/disengaged
by the mode fork, which operates the mode sleeve
and hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV243 21 - 659
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)

(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. 76).
(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) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case onto the transmission.
(5) Install and tighten transfer case attaching nuts
to 27-34 N´m (20-25 ft. lbs.) torque.
(6) Connect the vent hose.
(7) Connect the shift motor and mode sensor wir-
ing connectors. Secure wire harness to clips on trans-
fer case.
(8) Align and connect the propeller shafts.
(9) Fill transfer case with correct fluid. (Refer to
21 - TRANSMISSION/TRANSFER CASE/FLUID -
STANDARD PROCEDURE)
(10) Install skid plate, if equipped.
(11) Remove transmission jack and support stand.
(12) Lower vehicle and verify transfer case shift
operation.
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
Fig. 76 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
DRTRANSFER CASE - NV243 21 - 679
TRANSFER CASE - NV243 (Continued)