1998 DODGE RAM 1500 Rear seat

(7) Unseat rear case from alignment dowels.
(8) Remove the rear case from the front case (Fig.
13).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove the oil pick-up tube (Fig. 14) and
screen from the front case half.
(2) Remove the shift rail spring (Fig. 15).(3) Remove the front output shaft drive sprocket
retaining ring (Fig. 16).
Fig. 16 Remove Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 14 Remove Oil Pick-Up Tube and Screen
1 - FRONT CASE HALF
2 - OIL SCREEN
3 - PICK-UP TUBE
Fig. 15 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
DRTRANSFER CASE - NV271 21 - 453
TRANSFER CASE - NV271 (Continued)

(5) Remove the front output shaft front bearing
snap-ring from the front case half.
(6) Using Installer 6953 and Handle C-4171 (Fig.
46), remove the front output shaft front bearing.
(7) Start front output shaft front bearing in case.
Then seat bearing with Installer 8891 (Fig. 47).
(8)
Install front output shaft bearing retaining ring.
(9) 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. 48).(10) Install new pilot bearing with Installer 9035.
(11) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 49).
Fig. 46 Remove Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 47 Install Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - INSTALLER 8891
Fig. 48 Remove Input Gear Cup Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 49 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
21 - 462 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(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)

(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)

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.
(5) Tighten bolts to 27-34 N´m (20-25 ft. lbs.),
(6) Install rear output bearing inner snap-ring
(Fig. 84) to output shaft.
OIL PUMP AND REAR EXTENSION
(1) Install the oil pump (Fig. 85) onto the output
shaft.
Fig. 85 Install Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
Fig. 82 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 83 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 84 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
DRTRANSFER CASE - NV271 21 - 471
TRANSFER CASE - NV271 (Continued)

(7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
companion flange (Fig. 90).
(10) Install a new front companion flange nut.
Tighten the companion flange nut to 176-271 N´m
(130-200 ft.lbs.).
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV271
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Fig. 90 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
DRTRANSFER CASE - NV271 21 - 473
TRANSFER CASE - NV271 (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)