1998 DODGE RAM 1500 Workshop Manual

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Page 2193 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (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 t

Page 2194 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (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 out

Page 2195 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (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
h

Page 2196 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (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

Page 2197 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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 s

Page 2198 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual Inspect the shift fork wear pads (Fig. 41). The
mode and range fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teet

Inspect the shift fork wear pads (Fig. 41). The
mode and range fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing.
Replace both components if either show any sign of
wear or damage.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320-400 grit emery to
smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 42)
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoiltstain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
Fig. 41 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 42 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
DRTRANSFER CASE - NV243 21 - 495
TRANSFER CASE - NV243 (Continued)

Page 2199 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual ASSEMBLY
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 43) from
the front case with suitable snap-ring pliers.
(2) Transfer the retaining ring to the new bearing
if necessary and install

Page 2200 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (8) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 46).
(9) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 47). The bea

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