1998 DODGE RAM 1500 Drive shaft

CONDITION POSSIBLE CAUSE CORRECTION
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Transfer case will not shift through
4HI (Part-time) range.1) Incomplete shift due to drivetrain
torque load.1) Drive in a straight line and
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
REMOVAL
(1) Shift transfer case into AWD.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shafts for align-
ment reference.
(5) Support transmission with jack stand.
(6)
Remove the transfer case skid plate, if equipped.
(7) Disconnect front and rear propeller shafts at
transfer case.
(8) Disconnect transfer case shift motor and mode
sensor wire connectors.
(9) Disconnect transfer case vent hose.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission (Fig. 2).(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT
SHAFT SEAL
(1) Remove the bolts (Fig. 3) which hold the shift
motor and mode sensor assembly to the transfer
case.
Fig. 2 Remove Transfer Case - Typical
1 - TRANSMISSION
2 - TRANSFER CASE
3 - MODE SENSOR CONNECTOR
Fig. 3 Remove the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
21 - 514 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove rear case and oil pump assembly from
front case (Fig. 12).
(5) Remove the oil pump pickup tube.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail spring (Fig. 13).(2) Remove front sprocket retaining ring (Fig. 14).
(3) Remove the mode fork (Fig. 15) and sleeve
from the shift rail and mainshaft.
Fig. 12 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 13 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 14 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 15 Remove Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
DRTRANSFER CASE - NV244 GENII 21 - 517
TRANSFER CASE - NV244 GENII (Continued)

(4) Remove the rear output shaft retaining ring
(Fig. 16) from the output shaft.
(5) Pull front sprocket, rear sprocket, and chain
outward simultaneously (Fig. 17).
(6) Remove front sprocket, rear sprocket, and
chain as an assembly.
SHIFT FORKS AND MAINSHAFT
(1) Loosen detent plug.
(2) Remove detent plug, spring, and plunger (Fig.
18). Note that the plug has an O-ring seal. Remove
and discard this seal.
(3) Remove the front output shaft snap-ring (Fig.
19).
Fig. 18 Remove Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 19 Remove Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
Fig. 16 Remove Rear Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - RETAINING RING
Fig. 17 Remove Drive Sprockets and Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
21 - 518 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

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 and bearing surfaces.
Minor nicks on the splines can be smoothed with an
oilstone. Use 320-400 grit emery to smooth minor
scratches on the shaft bearing surfaces. Replace the
shaft if the bearing surfaces are scored or if any of
the splines 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. 41)
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 Fork and Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 41 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 524 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(14) Install the mainshaft and differential assem-
bly (Fig. 61) into the input gear and transfer case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft into the front out-
put shaft bearing.
(2) Install the front output shaft snap-ring (Fig.
62) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A(4) Install new o-ring on detent plug (Fig. 63).
NOTE: Shift the transfer case to the same range/
mode position it was in when the shift motor was
removed prior to installing the shift detent compo-
nents.
(5) Install detent plunger, spring, and plug (Fig.
64). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
Fig. 61 Install Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 62 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
Fig. 63 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 64 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
21 - 530 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

(6) Install the new front output shaft seal slinger
(Fig. 65) with Installer 8840. Install the slinger onto
the shaft until the tool contacts the front of the out-
put shaft.
(7) Install the front sprocket, rear sprocket, and
chain as an assembly.
(8) Lower the front sprocket, rear sprocket, and
chain over the front and rear output shafts simulta-
neously (Fig. 66) until fully seated on both splines.(9) Install the rear output shaft retaining ring
(Fig. 67) onto the output shaft.
(10) Install the front sprocket retaining ring (Fig.
68).
Fig. 65 Install Front Output Shaft Seal Slinger
1 - SEAL SLINGER
2 - INSTALLER 8840
Fig. 66 Install Drive Sprockets and Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
Fig. 67 Install Rear Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - RETAINING RING
Fig. 68 Installing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
DRTRANSFER CASE - NV244 GENII 21 - 531
TRANSFER CASE - NV244 GENII (Continued)

EXTENSION HOUSING SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Using Installer D-163, install seal in extension
housing (Fig. 79).
(3) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(4) Verify proper transfer case fluid level.
(5) Lower vehicle.
Installer, Bushing - 5066
Installer, Bearing - 6953
Cup - 8148
Installer - 8840
Installer, Seal - 8841
Fig. 79 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 536 TRANSFER CASE - NV244 GENIIDR
TRANSFER CASE - NV244 GENII (Continued)

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 80).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 20-34 N´m
(15-25 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, Automatic Transmis-
sion fluid.
(7) Install and tighten fill plug to 20-34 N´m
(15-25 ft. lbs.).
(8) Lower vehicle.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Remove the front propeller shaft (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL).
(2) Remove the front propeller shaft seal boot
retaining clamp (Fig. 81).
(3) Remove the front propeller shaft seal boot (Fig.
82).
Fig. 80 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 81 Remove Boot Clamp
1 - SEAL BOOT
2 - CLAMP
Fig. 82 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
DRTRANSFER CASE - NV244 GENII 21 - 537