1998 DODGE RAM 1500 Drive shaft

(2) Cycle the key from ACC to RUN and ensure
that the blocker does not stick or bind.
(3) Turn the key to the OFF position and ensure
that the shifter will not pull from the PARK position.
(4) Connect the over drive switch harness (if
equipped).
NOTE: Route and tie off harness to original loca-
tion.
(5) Connect the shift cable to the lever.
(6) Ensure the gear shift lever and transmission
are in the PARK position and snap the cable adjust
clip in place.
(7) Install a new brake light switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION).
(8) Install the SKIM and halo.
(9) Install the upper and lower column shroud.
(10) Install the column back into place and
tighten.
(11) Install the kneeblocker. (Refer to 23 - BODY/
INSTRUMENT PANEL/KNEE BLOCKER - INSTAL-
LATION).
UPPER STEERING COUPLING
REMOVAL
(1) Disconnect the negative battery cable.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.(2) Lock the steering wheel with the tire in the
straight position.
(3) Remove and discard the lower pinch bolt.
(4) Lower the steering coupler shaft from the col-
umn.
(5) Remove the upper steering coupling shaft seal
by pushing in the four tags securing it to the panel
(Fig. 16).
(6) Remove and discard the lower coupler pinch
bolt from the lower steering coupling shaft (Fig. 17).
(7) Remove the upper steering coupling shaft from
the vehicle (Fig. 17).
INSTALLATION
(1) Install the upper steering coupling shaft to the
vehicle (Fig. 17).
Fig. 15 GEAR SHIFT LEVER SPRING
1 - BLOCKER TO INHIBIT LINK SLOT
2 - GEAR SHIFT LEVER
Fig. 16 RELEASE TANGS
1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT
Fig. 17 UPPER STEERING COUPLER SHAFT
1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT
DRCOLUMN 19 - 13
GEAR SHIFT LEVER (Continued)

(2) Install the coupler to the intermediate shaft
using the marks made in the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.
(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
INSTALLATION - 4X4 HD
(1) Install the coupler to the steering gear.
(2) Install the coupler to the intermediate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) Install the lower pinch bolt and tighten to 28
N´m (250 in. lbs.).
(4) Install the upper pinch bolt and tighten to 57
N´m (42 ft. lbs.).
(5) Install the left front tire and wheel assembly
(Refer to 22 - TIRES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
(6) Lower the vehicle.(7) Reconnect the negative battery cable.
(8) Unlock the steering wheel.
STEERING WHEEL
REMOVAL
(1) Disable and remove the driver's side air-
bag.(Refer to 8 - ELECTRICAL/RESTRAINTS/
DRIVER AIRBAG - REMOVAL).
(2) Partially remove the steering wheel bolt and
leave the bolt in the column.
(3) Install puller CJ98-1 or equivalent using the
top of the bolt to push on. (Fig. 21)
(4) Remove and discard the steering wheel bolt.
(5) Remove the steering wheel.
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) Install steering wheel to the column
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) Install the new steering wheel bolt. Tighten the
bolt to 61 N´m (45 ft. lbs.).
(3) Install the driver's side air bag. (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
3 - LOWER COUPLING BOLT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DRCOLUMN 19 - 15
LOWER STEERING COUPLING (Continued)

NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(12) Remove oil seal from the housing with a spe-
cial tool 8990 with slide hammer C-3752. (Fig. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with a driver and handle
(Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the pitman arm (Refer to 19 - STEER-
ING/LINKAGE/PITMAN ARM - INSTALLATION).
INSTALLATION - DIESEL
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oil seal and washer withhigh temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) Install the oil seal with special tool 8989 driver
and C-4171 handle (Fig. 7).
(3) Install backup washer.
(4) Install the retainer ring with snap ring pliers.
(5) Coat the dust seal withhigh temp grease.
(6) Install the dust seal with special tool 8989
driver and C-4171 handle (Fig. 7).
(7) Install protective seal protector 8993 over the
shaft (Fig. 8).
(8) Install the pitman shaft into the steering gear
until it fully seats into the bearing.
(9) Install the new cover bolts and tighten to 68
N´m (50 ft. lbs.).
(10) Install the steering gear (Refer to 19 -
STEERING/GEAR - INSTALLATION).
Fig. 7 SEAL INSTALLATION
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8989
3 - STEERING GEAR
Fig. 8 PITMAN SHAFT SEAL PROTECTOR
1 - STEERING GEAR
2 - SPECIAL TOOL 8993
19 - 26 GEAR - LINK/COILDR
PITMAN SHAFT SEAL (Continued)

(7) Install the input shaft seal protector 8986 (Fig.
20).
(8) Coat the new seal inhigh temp greaseand
Install the new oil seal using special tool 8987 driver
and C-4171 handle (Fig. 21).
NOTE: Drive the oil seal into the housing until the
outer edge does not quite clear the snap ring
groove.
(9) Insert the snap ring into the housing. Using
special tool 8987 driver and C-4171 handle push the
snap ring and oil seal together until the snap ring
seats in the groove.NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(10) Install the new dust seal usinghigh temp
grease, special tool C-4171 (driver) and 8987 (han-
dle).
(11) Check to make sure the gear is centered in
the middle tooth before installing the pitman shaft
(Fig. 19).
(12) Install the pitman shaft into the steering gear
(Refer to 19 - STEERING/GEAR/PITMAN SHAFT -
INSTALLATION).
(13) Perform over-center meshload adjustment
(Refer to 19 - STEERING/GEAR - ADJUSTMENTS).
(14) Install the steering gear to the vehicle (Refer
to 19 - STEERING/GEAR - INSTALLATION).
(15) Perform a wheel alignment (Refer to 2 - SUS-
PENSION/WHEEL ALIGNMENT - STANDARD
PROCEDURE).
PITMAN SHAFT
REMOVAL
REMOVAL - GAS
(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the steering wheel from stop to stop and
count the number of turns.
(4) Center the steering wheel by rotating it from
the stop back 1 1/2 turns to achieve center position.
(5) Remove the pitman shaft cover bolts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove the pitman shaft from the gear (Fig.
22).
(7) Remove the cover if needed by loosing the
adjuster nut, Then removing the cover from the pit-
man shaft.
REMOVAL - DIESEL
(1) Separate the pitman arm from the gear box
(Refer to 19 - STEERING/LINKAGE/PITMAN ARM -
REMOVAL).
(2) Remove the steering gear box (Refer to 19 -
STEERING/GEAR - REMOVAL).
(3) Install the steering gear in a soft jawed bench
vise.
Fig. 20 INPUT SHAFT SEAL PROTECTOR
1 - INPUT SHAFT
2 - SPECIAL TOOL 8986
Fig. 21 INPUT SHAFT SEAL INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL 8987
3 - SPECIAL TOOL C-4171
19 - 30 GEAR - LINK/COILDR
STEERING GEAR INPUT SHAFT SEAL (Continued)

PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION.........................39
OPERATION...........................40
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 40
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION....40
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM............40
REMOVAL
REMOVAL - GAS......................41
REMOVAL - DIESEL...................41
INSTALLATION
INSTALLATION - GAS..................42
INSTALLATION - DIESEL................42
SPECIFICATIONS
TORQUE CHART......................42
FLUID
DESCRIPTION.........................43
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......43
FLUID COOLER
REMOVAL.............................43
INSTALLATION.........................43
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................44
REMOVAL - PRESSURE HOSE...........44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................44INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................44
INSTALLATION - PRESSURE HOSE.......44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............44
HOSES - LINK/COIL
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER............................45
REMOVAL - PRESSURE HOSE...........45
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER.........................45
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER............................45
INSTALLATION - PRESSURE HOSE.......45
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER...............45
POWER STEERING PRESSURE SWITCH
DESCRIPTION.........................46
OPERATION...........................46
REMOVAL - 3.7L & 5.7L..................46
INSTALLATION - 3.7L & 5.7L...............46
PULLEY
REMOVAL.............................47
INSTALLATION.........................47
RESERVOIR
REMOVAL.............................47
INSTALLATION.........................47
PUMP
DESCRIPTION
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.The pump is connected to the steering gear via the
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the
crankshaft pulley.
All vehicles are equipped with a power steering
fluid cooler.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
DRPUMP 19 - 39

OPERATION
Hydraulic pressure is provided for the power steer-
ing gear by the belt driven power steering pump (Fig.
1). The power steering pumps are constant flow rate
and displacement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump is serviced as an assembly and should
not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
Check for leaks in the following areas:
²Pump shaft seal behind the pulley
²Pump to reservoir O-ring
²Reservoir cap
²Pressure and return lines
²Flow control valve fitting
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: MOPARTATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
system. Damage may result to the power steeringpump and system if any other fluid is used, and do
not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicateCOLDwhen the fluid is
at normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.
(4) Slowly turn the steering wheel lock-to-lock 20
times with the engine off while checking the fluid
level.
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engine. With the engine idling main-
tain the fluid level.
(6) Lower the front wheels and let the engine idle
for two minutes.
(7) Turn the steering wheel in both direction and
verify power assist and quiet operation of the pump.
If the fluid is extremely foamy or milky looking,
allow the vehicle to stand a few minutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Plug the return line port/ports at the pump.
(4) Position the return line/lines into a large con-
tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fluid through the system then
stop the engine and install the return line/lines.
Fig. 1 POWER STEERING PUMP
1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP
19 - 40 PUMPDR
PUMP (Continued)

PULLEY
REMOVAL
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Remove the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - REMOVAL).
(2) Remove the pulley from the pump using (OTCt
7185) power steering pulley removal tool or equiva-
lent (Fig. 10).
INSTALLATION
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Replace the pulley if it's bent, cracked, or loose.
(2) Install the pulley on the pump using (OTCt
7771) power steering pulley installation tool or equiv-
alent (Fig. 11) making sure it is flush with the end of
the shaft. Ensure the tool and pulley remain aligned
with the pump shaft.
(3) Install the power steering pump assembly,
(Refer to 19 - STEERING/PUMP - INSTALLATION).
(4) Run engine until warm (5 min.) and note any
belt chirp. If chirp exists, move pulley outward
approximately 0.5 mm (0.020 in.). If noise increases,
press on 1.0 mm (0.040 in.).Be careful that pulley
does not contact mounting bolts.
RESERVOIR
REMOVAL
(1) Drain and siphon the power steering fluid from
the reservoir.
(2) Remove the serpentine belt.
(3) Remove the power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove the reservoir mounting bolts.
(5) Remove the reservoir.
(6) Remove the rear bracket to the pump mounting
bolts.
INSTALLATION
(1) Install the reservoir bracket to the pump hous-
ing.Do not reuse the o-rings (install new
o-rings).Tighten bolts to 7 N´m (62 in. lbs.).
NOTE: Ensure the reservoir is fully seated onto the
pump.
(2) Install the reservoir to the bracket/pump body.
(3) Install the reservoir mounting bolts. Tighten
bolts to 13 N´m (120 in. lbs.).
(4) Install the power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(5) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(6) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 10 PULLEY REMOVAL
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PULLEY REMOVAL TOOL
Fig. 11 PULLEY INSTALLATION
1 - POWER STEERING PUMP
2 - PULLEY
3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
DRPUMP 19 - 47

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500..........1
MANUAL TRANSMISSION - NV4500..........43
MANUAL TRANSMISSION - NV5600..........88
AUTOMATIC TRANSMISSION - 48RE........130
AUTOMATIC TRANSMISSION - 45RFE/545RFE.311
TRANSFER CASE - NV241 GENII...........415TRANSFER CASE - NV271................447
TRANSFER CASE - NV243................482
TRANSFER CASE - NV244 GENII...........512
TRANSFER CASE - NV273................542
MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING................3
REMOVAL.............................3
DISASSEMBLY..........................4CLEANING............................15
INSPECTION..........................16
ASSEMBLY............................17
INSTALLATION.........................39
SPECIFICATIONS.......................40
SPECIAL TOOLS.......................40
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmission is a medium-duty 5-speed, con-
stant mesh fully synchronized manual transmission
with fifth gear overdrive range. The transmission is
available in two and four-wheel drive configurations.
The transmission gear case consists of two aluminum
housings (Fig. 1). The clutch housing is an integral
part of the transmission front housing.
A combination of roller and ball bearings are used
to support the transmission shafts in the two hous-
ings. The transmission gears all rotate on caged type
needle bearings. A roller bearing is used between the
input and output shaft.
The transmission has a single shaft shift mecha-
nism with three shift forks all mounted on the shaft.
The shaft is supported in the front and rear housings
by bushings and one linear ball bearing. Internal
shift components consist of the forks, shaft, shift
lever socket and detent components
OPERATION
The manual transmission receives power through the
clutch assembly from the engine. The clutch disc issplined to the transmission input shaft and is turned at
engine speed at all times that the clutch is engaged.
The input shaft is connected to the transmission coun-
tershaft through the mesh of fourth speed gear on the
input shaft and the fourth countershaft gear. At this
point, all the transmission gears are spinning.
The driver selects a particular gear by moving the
shift lever to the desired gear position. This movement
moves the internal transmission shift components to
begin the shift sequence. As the shift lever moves the
selected shift rail, the shift fork attached to that rail
begins to move. The fork is positioned in a groove in the
outer circumference of the synchronizer sleeve. As the
shift fork moves the synchronizer sleeve, the synchro-
nizer begins to speed-up or slow down the selected gear
(depending on whether we are up-shifting or down-shift-
ing). The synchronizer does this by having the synchro-
nizer hub splined to the mainshaft and moving the
blocker ring into contact with the gear's friction cone. As
the blocker ring and friction cone come together, the
gear speed is brought up or down to the speed of the
synchronizer. As the two speeds match, the splines on
the inside of the synchronizer sleeve become aligned
with the teeth on the blocker ring and the friction cone
and eventually will slide over the teeth, locking the gear
to the mainshaft, or countershaft, through the synchro-
nizer.
DRTRANSMISSION AND TRANSFER CASE 21 - 1