1998 DODGE RAM 1500 Fig

FRONT AND REAR CASES
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 Helicoiltstain-
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. 42) 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.
(3) Remove the front output shaft bearing retain-
ing ring from inside the front case half.
(4) Using Installer 6436 and Handle C-4171,
remove front output shaft bearing.(5) Start front output shaft bearing in case. Then
seat bearing with Handle C-4171 and Installer 6953
(Fig. 43).
(6) Install front output shaft bearing retaining
ring.
(7) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 44).
Fig. 42 Remove Input Gear Bearing
1 - INPUT GEAR BEARING
2 - FRONT CASE
Fig. 43 Install Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6953
3 - HANDLE C-4171
Fig. 44 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
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TRANSFER CASE - NV244 GENII (Continued)

(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 45).
(9) Remove the rear output shaft bearing from the
rear case using Installer 5065 and Handle C-4171
(Fig. 46).
(10) Install the rear output shaft bearing (Fig. 47)
into the rear case using Remover/Installer 6953 and
Handle C-4171.
INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 48)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 48). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
Fig. 45 Front Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 46 Remove Rear Output Shaft Bearing
1 - HANDLE C-4171
2 - INSTALLER 5065
Fig. 47 Install Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 6953
3 - HANDLE C-4171
Fig. 48 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
21 - 526 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 49). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 50).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
NOTE: Replace the mode hub retainer if the legs
were distorted during removal.
(2) Install the mode hub retainer (Fig. 51) onto the
mode hub.
(3) Install the mode hub (Fig. 52) and mode hub
retainer onto the differential assembly. Make sure
the retainer is fully seated onto the differential.
Fig. 49 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 50 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 51 Install Retainer onto Mode Hub
1 - MODE HUB RETAINER
2 - MODE HUB
Fig. 52 Install the Mode Hub and Retainer
1 - DIFFERENTIAL ASSEMBLY
2 - MODE HUB AND RETAINER
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TRANSFER CASE - NV244 GENII (Continued)

(4) Install the differential assembly (Fig. 53) onto
the mainshaft.
(5) Install the differential snap-ring (Fig. 54).(6) Install the intermediate clutch shaft (Fig. 55).
(7) Install the clutch shaft thrust ring (Fig. 56).
Fig. 53 Install the Differential
1 - DIFFERENTIAL ASSEMBLY
2 - MAINSHAFT
Fig. 54 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 55 Installing Intermediate Clutch Shaft
1 - INTERMEDIATE CLUTCH SHAFT
Fig. 56 Installing Clutch Shaft Thrust Ring
1 - CLUTCH SHAFT THRUST RING
21 - 528 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(8) Install clutch shaft snap-ring (Fig. 57).
(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 58). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(10) Install the shift sector o-ring.(11) Assemble and install range fork and hub (Fig.
59). 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 shift rail (Fig. 60) into the range
fork assembly and the front case.
Fig. 57 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 58 Install Shift Sector
1 - SHIFT SECTOR
Fig. 59 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 60 Install Shift Rail
1 - SHIFT RAIL
2 - RANGE FORK ASSEMBLY
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TRANSFER CASE - NV244 GENII (Continued)

(14) Install the mainshaft and differential assem-
bly (Fig. 61) into the input gear and transfer case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft into the front out-
put shaft bearing.
(2) Install the front output shaft snap-ring (Fig.
62) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A(4) Install new o-ring on detent plug (Fig. 63).
NOTE: Shift the transfer case to the same range/
mode position it was in when the shift motor was
removed prior to installing the shift detent compo-
nents.
(5) Install detent plunger, spring, and plug (Fig.
64). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
Fig. 61 Install Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 62 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
Fig. 63 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 64 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
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TRANSFER CASE - NV244 GENII (Continued)

(6) Install the new front output shaft seal slinger
(Fig. 65) with Installer 8840. Install the slinger onto
the shaft until the tool contacts the front of the out-
put shaft.
(7) Install the front sprocket, rear sprocket, and
chain as an assembly.
(8) Lower the front sprocket, rear sprocket, and
chain over the front and rear output shafts simulta-
neously (Fig. 66) until fully seated on both splines.(9) Install the rear output shaft retaining ring
(Fig. 67) onto the output shaft.
(10) Install the front sprocket retaining ring (Fig.
68).
Fig. 65 Install Front Output Shaft Seal Slinger
1 - SEAL SLINGER
2 - INSTALLER 8840
Fig. 66 Install Drive Sprockets and Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
Fig. 67 Install Rear Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - RETAINING RING
Fig. 68 Installing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
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TRANSFER CASE - NV244 GENII (Continued)

(11) Inspect mode fork assembly (Fig. 69). Replace
pads if necessary. Also check springs and slider
bracket. Replace worn or damaged components.(12) Install the mode fork (Fig. 70) and sleeve over
the shift rail and mainshaft.
(13) Install spring onto the shift rail (Fig. 71).
(14) Insert magnet in front case pocket (Fig. 72).
Fig. 69 Mode Fork Assembly
1 - MODE FORK
2 - SPRING
Fig. 70 Install Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 71 Install Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 72 Install the Transfer Case Sump Magnet
1 - SUMP MAGNET
2 - CASE POCKET
21 - 532 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)