1998 DODGE RAM 1500 Transfer case

(10) Remove the shift sector support (Fig. 24).
(11) Remove shift sector (Fig. 25).MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
26) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
27) from the output shaft.
Fig. 24 Remove Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
Fig. 25 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 26 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 27 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
DRTRANSFER CASE - NV241 GENII 21 - 423
TRANSFER CASE - NV241 GENII (Continued)

(3) Remove drive sprocket (Fig. 28) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 29) and hub (Fig.
30) from the output shaft.
(5) Remove the mode hub retaining ring (Fig. 31)
from the output shaft.
Fig. 31 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 28 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
21 - 424 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)

DRIVE CHAIN
Examine the drive chain and shaft bearings.
replace the chain if stretched, distorted, or if any of
the links bind. Replace the bearings if rough, or
noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 43)
FRONT CASE AND REAR CASE
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with HelicoilŸ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 44) from
the front case with suitable snap-ring pliers.
(2) Transfer the retaining ring to the new bearing
if necessary and install the bearing into the front
case.
Fig. 42 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 43 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
Fig. 44 Remove Input Gear Bearing
1 - INPUT GEAR BEARING
2 - FRONT CASE
21 - 428 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(3) Using Installer 6436 and Handle C-4171 (Fig.
45), remove front output shaft bearing.
(4) Start front output shaft bearing in case. Then
seat bearing with Handle C-4171 and Installer 6953.
(5) Install front output shaft bearing retaining
ring.
(6) 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. 46).
(7) Install new pilot bearing with Remover/In-
staller 8684.(8) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 47).
Fig. 47 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 45 Remove Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6436
3 - HANDLE C-4171
Fig. 46 Remove Input Gear Cup Plug
1 - DRIFT
2 - INPUT GEAR
DRTRANSFER CASE - NV241 GENII 21 - 429
TRANSFER CASE - NV241 GENII (Continued)

(9) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 48). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 49).(10) Remove the rear output shaft bearing from
the rear case using Remover/Installer 8684 and Han-
dle C-4171 (Fig. 50).
(11) Install the rear output shaft bearing (Fig. 51)
into the rear case using Remover/Installer 6953 and
Handle C-4171.
Fig. 48 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 49 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 50 Remove Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 8684
3 - HANDLE C-4171
Fig. 51 Install Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 6953
3 - HANDLE C-4171
21 - 430 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)