1998 DODGE RAM 1500 FRONT HUB

(5) Remove front output shaft from bearing in case
(Fig. 20).
(6) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 21).(7) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 22). Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
(8) Remove range fork retaining ring.
(9) Remove range fork and hub as an assembly
(Fig. 23). Note fork position for installation reference.
Fig. 23 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 21 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 22 Remove Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
21 - 422 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(6) Remove the mode hub (Fig. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 34). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 35).
Fig. 35 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 33 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 34 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
DRTRANSFER CASE - NV241 GENII 21 - 425
TRANSFER CASE - NV241 GENII (Continued)

(2) Remove retainer (Fig. 36).
(3) Remove front tabbed thrust washer (Fig. 37).
(4) Remove input gear (Fig. 38).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 39).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3MŸ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone, however, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
Fig. 36 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 38 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 426 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 40). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 41). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 42). The
mode fork pads are serviceable and can be replaced if
necessary. The range fork pads are not serviceable.
The fork must be replaced as an assembly if the pads
are worn or damaged.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bear-
ing if rough or noisy. Check the retainer for cracks or
wear in the bearing bore.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended.
Inspect rear extension bushing. Replace if worn or
scored.
Fig. 40 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 41 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
DRTRANSFER CASE - NV241 GENII 21 - 427
TRANSFER CASE - NV241 GENII (Continued)

(11) Assemble and install range fork and hub (Fig.
64). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install the range fork retaining ring.
(14) Install mode fork and shift rail onto the mode
sleeve.
(15) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 65).(16) Install mainshaft into the transfer case (Fig.
66). Guide mainshaft through the mode and range
sleeves and into the input gear.
(17) Install the transfer case position sensor (Fig.
67). Tighten the sensor to 20-34 N´m (16-25 ft. lbs.)
torque.
Fig. 64 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 65 Install Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
Fig. 66 Install Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 67 Install Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
21 - 434 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(5) Install drive chain around mainshaft sprocket
(Fig. 73). Then position front sprocket over front
shaft.
(6) Raise mainshaft about 2.54 cm (one inch) and
seat front sprocket on front output shaft.
(7) If mainshaft and mode sleeve were unseated
during chain installation, align and reseat mainshaft
in input gear and hub.
(8) Install front sprocket retaining ring (Fig. 74).(9) Install spring and cup on shift rail (Fig. 75).
(10) Insert magnet in front case pocket (Fig. 76).
OIL PUMP AND REAR CASE
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) 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.
Fig. 73 Install Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 74 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 75 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 76 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
21 - 436 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(2) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 77).
(3) Install 4-5 rear case-to front case bolts (Fig. 78)
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.
(4) 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.),
(5) Install rear output bearing snap-ring (Fig. 79)
to output shaft.
SEAL BOOT
(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. 77 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 78 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 79 Install Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
DRTRANSFER CASE - NV241 GENII 21 - 437
TRANSFER CASE - NV241 GENII (Continued)

(4) Remove the front output shaft seal slinger by
bending (Fig. 85) the slinger ears away from the
transfer case.
(5) Using a suitable pry tool (Fig. 86), 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).
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. 87).
Fig. 85 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 86 Remove Slinger From Shaft
1 - SLINGER
2-PRYTOOL
21 - 442 TRANSFER CASE - NV241 GENIIDR
FRONT OUTPUT SHAFT SEAL (Continued)