1998 DODGE RAM 1500 Removal

PRESSURE SWITCHES
The TCM relies on five pressure switches to moni-
tor fluid pressure in the L/R, 2C, 4C, UD, and OD
hydraulic circuits. The primary purpose of these
switches is to help the TCM detect when clutch cir-
cuit hydraulic failures occur. The switches close at 23
psi and open at 11 psi, and simply indicate whether
or not pressure exists. The switches are continuously
monitored by the TCM for the correct states (open or
closed) in each gear as shown in the following charts
45RFE PRESSURE SWITCH STATES and 545RFE
PRESSURE SWITCH STATES :
45RFE PRESSURE SWITCH STATES
GEAR L/R 2C 4C UD OD
ROP OP OP OP OP
P/NCL OP OP OP OP
1STCL* OP OP CL OP
2NDOP CL OP CL OP
2ND
PRIMEOP OP CL CL OP
DOP OP OP CL CL
FOURTHOP OP CL OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
545RFE PRESSURE SWITCH STATES
GEAR L/R 2C 4C UD OD
ROP OP OP OP OP
P/NCL OP OP OP OP
1STCL* OP OP CL OP
2NDOP CL OP CL OP
2ND
PRIMEOP OP CL CL OP
DOP OP OP CL CL
4THOP OP CL OP CL
5THOP CL OP OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
A Diagnostic Trouble Code (DTC) will set if the
TCM senses any switch open or closed at the wrong
time in a given gear.
REMOVAL
(1) Remove the valve body from the transmission
(Fig. 127).
(2) Remove the screws holding the transmission
solenoid/TRS assembly onto the valve body (Fig. 128).
(3) Separate the transmission solenoid/TRS assem-
bly from the valve body.
Fig. 127 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 128 Transmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 407
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)

LOW/REVERSE SWITCH VALVE
The low/reverse switch valve allows the low/reverse
clutch to be operated by either the LR/CC solenoid or
the MS solenoid.
REMOVAL
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning
and inspection of the individual components. (Refer
to 21 - TRANSMISSION/AUTOMATIC - 45RFE/
VALVE BODY - DISASSEMBLY)
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Disconnect wires at the solenoid and pressure
switch assembly connector.
(4) Position drain pan under transmission oil pan.
(5) Remove transmission oil pan.
(6) Remove the primary oil filter from valve body.
(Fig. 132)
(7) Remove bolts attaching valve body to transmis-
sion case (Fig. 133).
(8) Lower the valve body and work the electrical
connector out of transmission case.
(9) Separate the valve body from the transmission.
DISASSEMBLY
(1) Remove the screws holding the solenoid and
pressure switch assembly to the valve body (Fig.
134). Do not remove the screws on the top of the sole-
noid and pressure switch assembly.
(2) Separate the solenoid and pressure switch
assembly from the valve body.
Fig. 132 Remove Primary Oil Filter
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 133 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 134 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
21 - 410 AUTOMATIC TRANSMISSION - 45RFE/545RFEDR
VALVE BODY (Continued)

TRANSFER CASE - NV241 GENII
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241 GENII
DESCRIPTION........................415
OPERATION..........................415
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV241 GENII..................416
REMOVAL............................417
DISASSEMBLY........................417
CLEANING...........................426
INSPECTION.........................426
ASSEMBLY...........................428
INSTALLATION........................438
SPECIFICATIONS
TRANSFER CASE - NV241 GENII........438
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243........439
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL............................440INSTALLATION........................440
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................441
FRONT OUTPUT SHAFT SEAL
REMOVAL............................441
INSTALLATION........................442
POSITION SENSOR
DESCRIPTION........................442
OPERATION..........................442
REMOVAL............................443
INSTALLATION........................443
SHIFT LEVER
REMOVAL............................444
INSTALLATION........................445
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER..........446
TRANSFER CASE - NV241
GENII
DESCRIPTION
The NV241 GENII transfer case is a part-time
transfer case with a low-range gear system. It pro-
vides three operating ranges plus a NEUTRAL posi-
tion. 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.
IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
OPERATING RANGE
Transfer case operating ranges are:
²2H (2-wheel drive)²4H (4-wheel drive)
²4LO (4-wheel drive low range)
The 2H range is for use on any road surface at any
time.
The 4H and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is covered by
ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DRTRANSFER CASE - NV241 GENII 21 - 415

Condition Possible Cause Correction
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.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Mark front and rear propeller shafts for assem-
bly reference.(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move 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.
DRTRANSFER CASE - NV241 GENII 21 - 417
TRANSFER CASE - NV241 GENII (Continued)

(2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 12).
(3) Unseat rear case from alignment dowels.
(4) Remove rear case and oil pump assembly from
front case (Fig. 13).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail cup and spring (Fig. 14).
(2) Remove front sprocket retaining ring (Fig. 15).
Fig. 12 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
Fig. 13 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
Fig. 15 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
21 - 420 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(5) Remove front output shaft from bearing in case
(Fig. 20).
(6) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 21).(7) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 22). Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
(8) Remove range fork retaining ring.
(9) Remove range fork and hub as an assembly
(Fig. 23). Note fork position for installation reference.
Fig. 23 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 21 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 22 Remove Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
21 - 422 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(6) Remove the mode hub (Fig. 32) 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. 33) with
heavy duty snap-ring pliers.(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 34). Tap gear out of bearing with plastic
mallet, if necessary.
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 35).
Fig. 35 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 33 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 34 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
DRTRANSFER CASE - NV241 GENII 21 - 425
TRANSFER CASE - NV241 GENII (Continued)

(2) Remove retainer (Fig. 36).
(3) Remove front tabbed thrust washer (Fig. 37).
(4) Remove input gear (Fig. 38).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 39).
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
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.
Fig. 36 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 38 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 426 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)