1998 DODGE RAM 1500 Transfer case

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)

(2) Remove front sprocket retaining ring (Fig. 15).
(3) Pull mainshaft, front sprocket and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
16).
(4) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as assembly.SHIFT FORKS AND MAINSHAFT
(1) Loosen detent plug.
(2) Remove detent plug, spring, and plunger (Fig.
17). Note that the plug has an O-ring seal. Remove
and discard this seal.
(3) Remove the front output shaft snap-ring (Fig.
18).
Fig. 15 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 16 Remove Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 17 Remove Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 18 Remove Front Output Shaft Snap-ring -
Typical
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
21 - 488 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

(4) Remove front output shaft from bearing in case
(Fig. 19).
(5) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 20).(6) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 21). Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
(7) Remove range fork retaining ring.
(8) Remove range fork and hub as an assembly
(Fig. 22). Note fork position for installation reference.
Fig. 22 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 19 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 20 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 21 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
DRTRANSFER CASE - NV243 21 - 489
TRANSFER CASE - NV243 (Continued)

(9) Remove shift sector (Fig. 23).
(10) Remove the shift sector o-ring (Fig. 24).MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
25) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
26) from the output shaft.
Fig. 23 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 24 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 25 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 26 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
21 - 490 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

(3) Remove drive sprocket (Fig. 27) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 28) and hub (Fig.
29) from the output shaft.
(5) Remove the mode hub retaining ring (Fig. 30)
from the output shaft.
Fig. 30 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 27 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 28 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 29 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
DRTRANSFER CASE - NV243 21 - 491
TRANSFER CASE - NV243 (Continued)

(6) Remove the mode hub (Fig. 31) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 32) with
heavy duty snap-ring pliers.(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 33). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 34).
Fig. 34 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 31 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 32 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 33 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
21 - 492 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

(2) Remove retainer (Fig. 35).
(3) Remove front tabbed thrust washer (Fig. 36).
(4) Remove input gear (Fig. 37).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 38).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3MŸ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
Fig. 35 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 36 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 37 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 38 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
DRTRANSFER CASE - NV243 21 - 493
TRANSFER CASE - NV243 (Continued)

INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 39). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 40). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Fig. 39 Input Gear and Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 40 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
21 - 494 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)