1998 DODGE RAM 1500 Engine Installation

(6) Remove cable housing from dash panel and
pull cable into engine compartment.
(7) Remove cable housing at APPS bracket by
pressing on release tab with a small screwdriver.Toprevent cable housing breakage, press on tab
only enough to release cable from APPS
bracket.
INSTALLATION
Accelerator Pedal Position Sensor Mounted To Engine
(1) Install cable through mounting hole on cable
mounting bracket (Fig. 34). Cable snaps into bracket.
Be sure 2 pinch tabs are secure.
(2) Using large pliers, connect cable end socket to
throttle lever ball (snaps on).
(3) Install remaining cable housing end into and
through dash panel opening (snaps into position).
The two plastic pinch tabs should lock cable to dash
panel.
(4) From inside vehicle, hold up accelerator pedal.
Install throttle cable core wire and plastic cable
retainer into and through upper end of pedal arm
(the plastic retainer is snapped into pedal arm).
When installing plastic retainer to accelerator pedal
arm, note index tab on pedal arm (Fig. 32). Align
index slot on plastic cable retainer to this index tab.
(5) Connect negative battery cables to both batter-
ies.
(6) Before starting engine, operate accelerator
pedal to check for any binding.
(7) Install cable/lever cover.
Fig. 32 ACCELERATOR PEDAL MOUNTING
1 - ACCELERATOR CABLE
2 - PLASTIC RETAINER (CLIP)
3 - THROTTLE PEDAL ARM
4 - PEDAL / BRACKET ASSEMBLY
5 - CABLE CLIP
Fig. 33 CABLE/LEVER/THROTTLE LINKAGE COVER
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 34 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
10 - SPEED CONTROL CABLE
14 - 84 FUEL INJECTION - DIESELDR
THROTTLE CONTROL CABLE (Continued)

GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................21
ADJUSTMENTS
ADJUSTMENT........................21
SPECIFICATIONS
POWER STEERING GEAR..............22
TORQUE CHART......................23
SPECIAL TOOLS
POWER STEERING GEAR..............23
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE...............25REMOVAL - DIESEL...................25
INSTALLATION
INSTALLATION - GAS ENGINE...........26
INSTALLATION - DIESEL................26
STEERING GEAR INPUT SHAFT SEAL
REMOVAL.............................27
INSTALLATION.........................29
PITMAN SHAFT
REMOVAL
REMOVAL - GAS......................30
REMOVAL - DIESEL...................30
INSTALLATION
INSTALLATION - GAS..................31
INSTALLATION - DIESEL................31
GEAR - LINK/COIL
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
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.
(3) Siphon out as much power steering fluid as
possible.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
19 - 20 GEAR - LINK/COILDR

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)

INSTALLATION
INSTALLATION - GAS
(1) Align the pump with the mounting holes in the
left cylinder head.
(2) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(3) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(4) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
INSTALLATION - DIESEL
(1) Set the power steering pump in place in the
engine compartment from the top (Fig. 3).(2) Install the inner cooler tube.
(3) Tighten the inner cooler tube clamp at the
radiator support side.
(4) Install the 6 intake plenum bolts (Fig. 3).
(5) Tighten the inner cooler tube clamp at the
intake plenum.
(6) Install 3 pump mounting bolts through the pul-
ley access holes. Tighten the bolts to 28 N´m (21 ft.
lbs.).
(7) Tighten the pump bracket to the block.
(8) Reconnect the pressure line and return hose to
the pump and reservoir. Tighten the pressure line to
37 N´m (27 ft. lbs.).
(9) Install the serpentine drive belt, (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Fill the power steering pump, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pressure
Switch10 Ð 80
Power Steering Line
Pressure Line32 23 Ð
Power Steering Line
Return Line
HD51 38 Ð
Power Steering Line
Return Line
LD70 52 Ð
Power Steering Line
Pressure Line To Pump37 27 Ð
Power Steering Pump
Mounting Bolts28 27 Ð
Power Steering Pump
Reservoir Bolts13 10 120
Power Steering Pump
Bracket Bolts5562
19 - 42 PUMPDR
PUMP (Continued)

FLUID
DESCRIPTION
The recommended fluid for the power steering sys-
tem is MopartATF +4.
MopartATF+4, when new is red in color. The
ATF+4 is dyed red so it can be identified from other
fluids used in the vehicle such as engine oil or anti-
freeze. The red color is not permanent and is not an
indicator of fluid condition, As the vehicle is driven,
the ATF+4 will begin to look darker in color and may
eventually become brown.THIS IS NORMAL.
ATF+4 also has a unique odor that may change with
age. Consequently, odor and color cannot be used to
indicate the fluid condition or the need for a fluid
change.
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
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 power steering fluid level can be viewed on the
dipstick attached to the filler cap. There are two
ranges listed on the dipstick, COLD and HOT. Before
opening power steering system, wipe the reservoir
filler cap free of dirt and debris. Remove the cap and
check the fluid level on its dipstick. When the fluid is
at normal ambient temperature, approximately 21ÉC
to 27ÉC (70ÉF to 80ÉF), the fluid level should read
between the minimum and maximum area of the cold
range. When the fluid is hot, fluid level is allowed to
read up to the highest end of the HOT range. Only
add fluid when the vehicle is cold.
Use only MopartATF+4Do not overfill the
power steering system.
FLUID COOLER
REMOVAL
(1) Drain and siphon the power steering fluid.
(2) Disconnect the return and supply hoses con-
nected to the power steering fluid cooler.
(3) Remove the mounting bracket bolts securing
the fluid cooler to the brace. (Fig. 4)& (Fig. 5)(4) Remove the fluid cooler from the vehicle.
INSTALLATION
(1) Install the fluid cooler to the vehicle.
(2) Install the mounting bracket bolts securing the
fluid cooler to the brace (Fig. 4)& (Fig. 5).
(3) Reclamp the return and supply hoses to the
power steering fluid cooler.
(4) Refill the power steering fluid (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
Fig. 4 V6 & V8 P/S FLUID COOLER
1 - POWER STEERING FLUID COOLER
2 - MOUNTING BOLTS
Fig. 5 V10 & DIESEL P/S FLUID COOLER
1 - RADIATOR
2 - POWER STEERING HOSES
3 - MOUNTING BOLTS
4 - P/S FLUID COOLER
DRPUMP 19 - 43

(4) Remove the support and lower the vehicle.
(5) Reconnect the return hose at the reservoir.
(6) Refill the power steering system,(Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensing switch is used in the power
steering system. It is mounted on the high-pressure
steering hose (Fig. 9). This switch will be used with
both 3.7L and 5.7L engines. There is no pressure
switch used for the 4.7L or the 5.9L pump.
OPERATION
The switch is used on the 3.7L V-6 & 5.7L V-8
engines.
The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
input is provided during periods of high steering
pump load and low engine rpm; such as during park-
ing maneuvers. The PCM increases the idle speed
through the Idle Air Control (IAC) motor. This is
done to prevent the engine from stalling under the
increased load.
When steering pump pressure exceeds 3275 kPa  
690 kPa (475 psi   100 psi), the Normally Closed
(NC) switch will open and the PCM will increase the
engine idle speed. This will prevent the engine from
stalling.
When pump pressure drops to approximately 1379
kPa (200 psi), the switch circuit will re-close and
engine idle speed will return to its previous setting.
REMOVAL - 3.7L & 5.7L
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 9).
(1) Disconnect electrical connector from power
steering pressure switch.(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION - 3.7L & 5.7L
This switch is used only with the 3.7L V±6 and the
5.7L V-8 engines.
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 8±11 N´m (70±100 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
Fig. 9 PRESSURE SWITCH
1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
19 - 46 PUMPDR
HOSES - LINK/COIL (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