1998 DODGE RAM 1500 Workshop Manual

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Page 2225 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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 horiz

Page 2226 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (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 stan

(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.
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. Minor nicks on the shift rail can be
smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 40). 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.
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 - NV244 GENII 21 - 523
TRANSFER CASE - NV244 GENII (Continued)

Page 2227 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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 splines a

Page 2228 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual 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

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.
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 42) from
the front case with suitable snap-ring pliers.
(2) Transfer the retaining ring to the new bearing
if necessary and install the bearing into the front
case.
(3) Remove the front output shaft bearing retain-
ing ring from inside the front case half.
(4) Using Installer 6436 and Handle C-4171,
remove front output shaft bearing.(5) Start front output shaft bearing in case. Then
seat bearing with Handle C-4171 and Installer 6953
(Fig. 43).
(6) Install front output shaft bearing retaining
ring.
(7) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 44).
Fig. 42 Remove Input Gear Bearing
1 - INPUT GEAR BEARING
2 - FRONT CASE
Fig. 43 Install Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6953
3 - HANDLE C-4171
Fig. 44 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
DRTRANSFER CASE - NV244 GENII 21 - 525
TRANSFER CASE - NV244 GENII (Continued)

Page 2229 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 45).
(9) Remove the rear output shaft bearing from the
rear case using Installer 5065 and Handle C-4171
(Fig. 46).
(10) Install

Page 2230 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6)

Page 2231 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (4) Install the differential assembly (Fig. 53) onto
the mainshaft.
(5) Install the differential snap-ring (Fig. 54).(6) Install the intermediate clutch shaft (Fig. 55).
(7) Install the clutch shaft t

Page 2232 of 2627

DODGE RAM 1500 1998 2.G Workshop Manual (8) Install clutch shaft snap-ring (Fig. 57).
(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 58). Position slot
in sector so it will be aligned with shift fo

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