1998 DODGE RAM 1500 Alignment

SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Raise and support the vehicle.
(3) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(4) Lower vehicle.
(5) Remove transfer case shifter knob cap.
(6) Remove nut holding shifter knob to shift lever.
(7) Remove shifter knob.
(8) Remove the shift boot from the shifter console.
(9) Remove the bolts securing the shifter mecha-
nism to the floor pan (Fig. 97).
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 97 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV271 21 - 479

INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 98).
(2) Position shift lever in vehicle.
(3) Install the bolts to hold the shifter mechanism
to the floor pan.
(4) Raise vehicle.
(5) Verify that the transfer case is still in the 2H
position. The 2H detent position on the transfer case
shift arm is the second position from full forward.(6) Install trunnion to shift lever, if necessary.
(7) Install shift rod to trunnion, if necessary.
(8) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(9) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(10) Lower vehicle.
(11) Install the transfer case shifter console.
(12) Install the shifter boot and the shifter knob
onto the shifter lever.
(13) Install nut to hold shifter knob to shift lever.
(14) Install shifter knob cap.
(15) Verify transfer case operation.
Fig. 98 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 480 TRANSFER CASE - NV271DR
SHIFT LEVER (Continued)

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 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
DRTRANSFER CASE - NV271 21 - 481
SHIFT LEVER (Continued)

OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bolts (Fig. 11).
(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 12).(3) Unseat rear case from alignment dowels.
(4) Remove rear case and oil pump assembly from
front case (Fig. 13).
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.
(5) Remove the oil pump pickup tube.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail cup and spring (Fig. 14).
Fig. 11 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 12 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
Fig. 13 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
DRTRANSFER CASE - NV243 21 - 487
TRANSFER CASE - NV243 (Continued)

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.
Fig. 73 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
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
21 - 504 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

(2) Remove rear extension housing (Fig. 8). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 9).
OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bolts (Fig. 10).
(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 11).
(3) Unseat rear case from alignment dowels.
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.
Fig. 8 Remove Rear Extension
1 - EXTENSION HOUSING
2 - TRANSFER CASE
3 - PRY SLOT
Fig. 9 Remove Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 10 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 11 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
21 - 516 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

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, if necessary.
(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 rear output bearing snap-ring (Fig. 74)
to output shaft.
(6) Install 4-5 rear case-to front case bolts (Fig. 75)
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.(7) Apply MopartLock 'n Seal Adhesive to remain-
der of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 N´m (18-21 ft. lbs.),
Fig. 73 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 74 Install Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 75 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
DRTRANSFER CASE - NV244 GENII 21 - 533
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove the rear output shaft bearing inner
snap-ring (Fig. 10) from the output shaft using suit-
able snap-ring pliers.
(5) Remove the rear output shaft bearing inner
snap-ring (Fig. 11) from the output shaft.
(6) Loosen rear case with pry tool to break sealer
bead. Insert tool at each end of case (Fig. 12).
(7) Unseat rear case from alignment dowels.
(8) Remove the rear case from the front case (Fig.
13).
Fig. 10 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 11 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 12 Separate Front and Rear Case Halves
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
DRTRANSFER CASE - NV273 21 - 547
TRANSFER CASE - NV273 (Continued)