1998 DODGE RAM 1500 torque

(11) Assemble and install range fork and hub (Fig.
64). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install the range fork retaining ring.
(14) Install mode fork and shift rail onto the mode
sleeve.
(15) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 65).(16) Install mainshaft into the transfer case (Fig.
66). Guide mainshaft through the mode and range
sleeves and into the input gear.
(17) Install the transfer case position sensor (Fig.
67). Tighten the sensor to 20-34 N´m (16-25 ft. lbs.)
torque.
Fig. 64 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 65 Install Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
Fig. 66 Install Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 67 Install Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
21 - 434 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(18) Install range lever on sector shaft (Fig. 68).
(19) Install washer and nut on sector shaft to
secure shift lever. Apply 1-2 drops MopartLock N'
Seal, or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N´m (20-25 ft. lbs.) torque.
(20) Install new o-ring on detent plug (Fig. 69).
(21) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 71) into the
front output shaft bearing.
(2) Install the front output shaft retaining ring
(Fig. 72) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(4) Insert front sprocket in drive chain.
Fig. 68 Install Range Lever Nut
1 - RANGE LEVER
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 71 Install Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 72 Install Front Output Shaft Snap-ring
1 - FRONT OUTPUT SHAFT
2 - SNAP-RING
DRTRANSFER CASE - NV241 GENII 21 - 435
TRANSFER CASE - NV241 GENII (Continued)

(2) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 77).
(3) Install 4-5 rear case-to front case bolts (Fig. 78)
to hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts. Case
could be cracked if shaft rail or dowels are mis-
aligned.
(4) Apply LoctiteŸ 242 to remainder of rear case-
to-front case bolt threads and install bolts. Tighten
bolts to 20-27 N´m (15-24 ft. lbs.),
(5) Install rear output bearing snap-ring (Fig. 79)
to output shaft.
SEAL BOOT
(1) Install the front output shaft seal slinger with
Installer 8840. Install the slinger onto the shaft until
the tool contacts the rear of the output shaft.
(2) Install a new seal boot clamp onto the seal
boot.
(3)
Install the seal boot and clamp onto the slinger
hub and tighten the clamp with Crimp Tool C-4975-A.
Fig. 77 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 78 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 79 Install Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
2 - OUTPUT SHAFT BEARING
3 - RETAINING RING
4 - TRANSFER CASE
DRTRANSFER CASE - NV241 GENII 21 - 437
TRANSFER CASE - NV241 GENII (Continued)

REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(3) Align and install rear extension on retainer
(Fig. 80).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.
(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 438 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm  0.5mm
2 - POSITION 2 - 12mm  0.5mm
3 - POSITION 3 - 14mm  0.5mm
4 - POSITION 4 - 16mm  0.5mm
5 - POSITION 5 - 18mm  0.5mm
6 - POSITION 6 - 20mm 0.5mm - FULL EXTENSION
DRTRANSFER CASE - NV241 GENII 21 - 443
POSITION SENSOR (Continued)

ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion.
(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion. Lubricate the shift rod
and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H
detent position. The 2H detent position on the trans-
fer case shift arm is the second position from full for-
ward.
(6) Align the adjustment locating hole on the lower
shifter lever with the adjustment channel on the
shifter bracket assembly (Fig. 90).(7) Insert an appropriately sized pin through into
the adjustment channel and through the locating
hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N´m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans-
fer case shifts into and operates properly in all
ranges.
Fig. 90 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
21 - 446 TRANSFER CASE - NV241 GENIIDR
SHIFT LEVER (Continued)

TRANSFER CASE - NV271
TABLE OF CONTENTS
page page
TRANSFER CASE - NV271
DESCRIPTION........................447
OPERATION..........................448
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV271.......................448
REMOVAL............................450
DISASSEMBLY........................450
CLEANING...........................459
INSPECTION.........................459
ASSEMBLY...........................461
INSTALLATION........................473
SPECIFICATIONS
TRANSFER CASE - NV271.............473
SPECIAL TOOLS
TRANSFER CASE NV271/NV273.........474
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL............................476INSTALLATION........................476
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................476
FRONT OUTPUT SHAFT SEAL
REMOVAL............................477
INSTALLATION........................477
POSITION SENSOR
DESCRIPTION........................477
OPERATION..........................477
REMOVAL............................478
INSTALLATION........................478
SHIFT LEVER
REMOVAL............................479
INSTALLATION........................480
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER..........481
TRANSFER CASE - NV271
DESCRIPTION
The NV271 transfer case is a part-time transfer
case with a low-range gear system. It provides three
operating ranges plus a NEUTRAL position. The low
range position provides a gear reduction ratio of
2.72:1 for increased low speed torque capability.
The gear cases and extension are all of aluminum
(Fig. 1). Drive sprockets and an interconnecting drive
chain are used to transmit engine torque to the front/
rear propeller shafts. The mainshaft, input gear and
front output shaft are supported by ball and needle
bearings.
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DRTRANSFER CASE - NV271 21 - 447

DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will not
shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into desired
range. Or, reduce speed to below 3-4
km/h (2-3 mph) before attempting the
shift.
2) If vehicle was operated for an
extended period in 4H on a dry paved
surface, the driveline torque load may
be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate vehicle
in 2H on dry paved surfaces.
3) Transfer case external shift linkage
binding.3) Lubricate, repair, or replace linkage
bushings, or tighten loose components
as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
5) Internal components binding, worn,
or damaged.5) Disassemble the transfer case and
replace worn or damaged components
as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, Automatic
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in NEUTRAL,
or the clutch depressed in the case of a
manual transmission and the vehicle
moving under 3-4 km/h (2-3 mph), shift
the transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair linkage as
necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or damaged. 5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft seal
or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct level.
2) Vent closed or restricted. 2) Clear or replace vent as necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary. Check to
ensure that another component, the
propeller shaft slip yoke for example, is
not causing damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H position on
hard, dry surfaces.
DRTRANSFER CASE - NV271 21 - 449
TRANSFER CASE - NV271 (Continued)