1998 DODGE RAM 1500 Transfer case

(12) Install new bearing with Tool Handle C-4171
and Installer 8128 (Fig. 50). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 51).(13) Remove seal from oil pump with suitable pry
tool.
(14) Install new seal in oil pump with Installer
7888 (Fig. 52).
(15) Remove the rear output shaft bearing snap-
ring (Fig. 53) from the rear case half.
Fig. 53 Remove Rear Output Bearing Outer
Snap-Ring
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT BEARING
3 - SNAP-RING
Fig. 50 Install Front Output Shaft Rear Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8128
Fig. 51 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 52 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
DRTRANSFER CASE - NV271 21 - 463
TRANSFER CASE - NV271 (Continued)

(16) Remove the rear output shaft bearing from
the rear case using Installer 7888 (Fig. 54).
(17) Install the rear output shaft bearing (Fig. 55)
into the rear case using Installer 8152 and Handle
C-4171.
(18) Install the rear output shaft bearing snap-
ring into the rear case half.INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers with rec-
ommended transmission fluid.
(2) Install bottom thrust washer (Fig. 56) in low
range gear planetary. Be sure washer tabs are prop-
erly aligned in gear notches.
(3) Install input gear in low range gear (Fig. 57).
Be sure input gear is fully seated.
Fig. 54 Remove Rear Output Shaft Bearing
1 - REAR CASE HALF
2 - INSTALLER 7888
Fig. 55 Install Rear Output Shaft Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8152
Fig. 56 Install Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
Fig. 57 Install Input Gear From Planetary
1 - INPUT GEAR
2 - LOW RANGE PLANETARY
21 - 464 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(4) Install remaining thrust washer (Fig. 58) in
low range gear and on top of input gear.
(5) Install retainer (Fig. 59) on input gear and
install snap-ring (Fig. 60).
(6) Align and install low range/input gear assem-
bly in front case (Fig. 61). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
Fig. 61 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 58 Install Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 59 Install Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
Fig. 60 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
DRTRANSFER CASE - NV271 21 - 465
TRANSFER CASE - NV271 (Continued)

(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 62).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.
(9) Install a new input gear oil seal with Installer
9036 and Handle C-4171.
SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (Fig.
63) onto the mainshaft.(3) Install the mode hub (Fig. 64) onto the main-
shaft.
(4) Install the mode hub retaining ring (Fig. 65)
onto the mainshaft.
Fig. 62 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 63 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 64 Install Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 65 Install Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
21 - 466 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(5) Install the clutch gear (Fig. 66) onto the output
shaft. Verify that the pointed ends of the clutch gear
teeth are pointing to the front of the mainshaft.
(6) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 67). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(7) Apply LoctiteŸ 242, or equivalent, to the
threads of the sector support to replentish the factory
applied patch. Install the shift sector support.
Tighten the sector support with Socket 9033 to 27-34
N´m (20-25 ft.lbs.).(8) Assemble and install range fork and hub (Fig.
68). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(9) Align and insert range fork pin in shift sector
slot.
(10) Install mode fork and shift rail onto the mode
sleeve.
(11) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 69).
Fig. 66 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 67 Install Shift Sector
1 - SHIFT SECTOR
Fig. 68 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 69 Install Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
DRTRANSFER CASE - NV271 21 - 467
TRANSFER CASE - NV271 (Continued)

(12) Install mainshaft into the transfer case (Fig.
70). Guide mainshaft through the mode and range
sleeves and into the input gear.
(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).
Fig. 73 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
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
21 - 468 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(17) Install detent plunger, spring, and plug (Fig.
74). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 75) into the
front output shaft front bearing.
(2) Install the front output shaft bearing inner
snap-ring (Fig. 76) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front drive sprocket in drive chain.
(5) Install drive chain around rear drive sprocket.(6) Position rear drive sprocket (Fig. 77) over the
output shaft and lower the sprocket and chain
assembly until the front sprocket is positioned over
the front output shaft.
(7) Align the splines in the sprockets to the splines
on the output shafts and install the sprockets onto
the output shafts.
Fig. 74 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
Fig. 75 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 76 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 77 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
DRTRANSFER CASE - NV271 21 - 469
TRANSFER CASE - NV271 (Continued)

(8) Install front sprocket retaining ring (Fig. 78).
(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 sealer
bead 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.
Fig. 78 Install Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
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
21 - 470 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)