2003 DODGE RAM 5 speed manual transmission
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power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sectoroperates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV241 GENII
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
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.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 592 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)
Page 2463 of 2895
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The transfer case can be shifted between the 2H
and 4H operating ranges while the vehicle is in
motion. The vehicle must have the transmission
placed in NEUTRAL, or the clutch depressed in the
case of a manual transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
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.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 624 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)
Page 2878 of 2895
NV4500 - SPECIFICATIONS, MANUAL
TRANSMISSION......................21-79
NV5600 - ASSEMBLY, MANUAL
TRANSMISSION.....................21-105
NV5600 - DESCRIPTION, MANUAL
TRANSMISSION......................21-87
NV5600 - DIAGNOSIS AND TESTING,
MANUAL TRANSMISSION..............21-89
NV5600 - DISASSEMBLY, MANUAL
TRANSMISSION......................21-90
NV5600 - INSPECTION, MANUAL
TRANSMISSION.....................21-104
NV5600 - INSTALLATION, MANUAL
TRANSMISSION.....................21-120
NV5600 - OPERATION, MANUAL
TRANSMISSION......................21-89
NV5600 - REMOVAL, MANUAL
TRANSMISSION......................21-89
NV5600 - SPECIAL TOOLS, MANUAL
TRANSMISSION.....................21-122
NV5600 - SPECIFICATIONS............21-122
ODOMETER - DESCRIPTION............8J-31
ODOMETER - OPERATION..............8J-31
OFF INDICATOR - DESCRIPTION,
OVERDRIVE.........................8J-33
OFF INDICATOR - OPERATION,
OVERDRIVE.........................8J-33
OIL - DESCRIPTION, REFRIGERANT......24-54
OIL - OPERATION, REFRIGERANT........24-54
OIL - STANDARD PROCEDURE, ENGINE . . 9-269,
9-396
OIL AND LUBRICANTS - DESCRIPTION,
ENGINE..............................0-2
OIL COOLER - INSTALLATION, AIR TO.....7-75
OIL COOLER - REMOVAL, AIR TO.........7-74
OIL COOLER - REMOVAL, WATER TO......7-74
OIL FILTER - INSTALLATION . 9-153,9-217,9-270,
9-342,9-397,9-70
OIL FILTER - REMOVAL.....9-152,9-216,9-270,
9-342,9-397,9-69
OIL LEAK - DIAGNOSIS AND TESTING,
ENGINE...................9-150,9-214,9-63
OIL LEAKS - DIAGNOSIS AND TESTING,
ENGINE.......................9-269,9-394
OIL LEVEL - STANDARD PROCEDURE,
ENGINE............................9-341
OIL LEVEL - STANDARD PROCEDURE,
REFRIGERANT.......................24-54
OIL PAN - CLEANING . . . 9-270,9-342,9-397,9-65
OIL PAN - DESCRIPTION................9-65
OIL PAN - INSPECTION . . 9-271,9-342,9-397,9-66
OIL PAN - INSTALLATION . . . 9-153,9-217,9-271,
9-342,9-398,9-66
OIL PAN - REMOVAL . . 9-153,9-217,9-270,9-342,
9-397,9-65
OIL PRESSURE - DIAGNOSIS AND
TESTING, CHECKING ENGINE . . 9-150,9-214,9-64
OIL PRESSURE - DIAGNOSIS AND
TESTING, ENGINE..........9-269,9-338,9-396
OIL PRESSURE GAUGE - DESCRIPTION . . . 8J-32
OIL PRESSURE GAUGE - OPERATION.....8J-32
OIL PRESSURE RELIEF VALVE -
CLEANING..........................9-343
OIL PRESSURE RELIEF VALVE -
INSPECTION........................9-343
OIL PRESSURE RELIEF VALVE -
INSTALLATION.......................9-343
OIL PRESSURE RELIEF VALVE -
REMOVAL..........................9-343
OIL PRESSURE SENSOR/SWITCH -
DESCRIPTION........................9-66
OIL PRESSURE SENSOR/SWITCH -
INSTALLATION...................9-343,9-67
OIL PRESSURE SENSOR/SWITCH -
OPERATION..........................9-66
OIL PRESSURE SENSOR/SWITCH -
REMOVAL......................9-343,9-67
OIL PUMP - ASSEMBLY......9-156,9-274,9-68
OIL PUMP - ASSEMBLY . . 21-215,21-393,21-566
OIL PUMP - CLEANING . 9-155,9-218,9-344,9-398
OIL PUMP - CLEANING
. . . 21-214,21-393,21-566
OIL PUMP - DESCRIPTION
......21-212,21-392,
21-562
OIL PUMP - DISASSEMBLY
. . . 9-155,9-272,9-67
OIL PUMP - DISASSEMBLY
.....21-212,21-393,
21-564
OIL PUMP - INSPECTION
....9-155,9-218,9-272,
9-344,9-399,9-67OIL PUMP - INSPECTION . 21-214,21-393,21-566
OIL PUMP - INSTALLATION . . 9-157,9-219,9-274,
9-344,9-400,9-68
OIL PUMP - OPERATION . . 21-212,21-392,21-562
OIL PUMP - REMOVAL......9-154,9-218,9-272,
9-343,9-398,9-67
OIL PUMP FRONT SEAL - INSTALLATION . 21-567
OIL PUMP FRONT SEAL - REMOVAL....21-567
OIL PUMP VOLUME CHECK - STANDARD
PROCEDURE.......................21-563
OIL SEAL - FRONT - DESCRIPTION,
CRANKSHAFT.......................9-254
OIL SEAL - FRONT - INSTALLATION,
CRANKSHAFT....9-134,9-203,9-255,9-324,9-45
OIL SEAL - FRONT - OPERATION,
CRANKSHAFT.......................9-254
OIL SEAL - FRONT - REMOVAL,
CRANKSHAFT....9-134,9-203,9-254,9-323,9-44
OIL SEAL - FRONT COVER INSTALLED -
INSTALLATION, FRONT................9-384
OIL SEAL - FRONT COVER INSTALLED -
REMOVAL, FRONT....................9-384
OIL SEAL - FRONT COVER REMOVED -
INSTALLATION, FRONT................9-384
OIL SEAL - FRONT COVER REMOVED -
REMOVAL, FRONT....................9-384
OIL SEAL - REAR - DESCRIPTION,
CRANKSHAFT.......................9-255
OIL SEAL - REAR - INSTALLATION,
CRANKSHAFT . . . 9-136,9-204,9-256,9-325,9-385,
9-46
OIL SEAL - REAR - OPERATION,
CRANKSHAFT.........................9-255
OIL SEAL - REAR - REMOVAL,
CRANKSHAFT . . . 9-135,9-204,9-255,9-325,9-385,
9-45
OIL SEAL RETAINER - INSTALLATION,
CRANKSHAFT REAR........9-205,9-326,9-386
OIL SEAL RETAINER - REMOVAL,
CRANKSHAFT REAR........9-204,9-326,9-386
OIL SERVICE - STANDARD PROCEDURE,
ENGINE..............9-151,9-215,9-341,9-70
ON-BOARD DIAGNOSTICS (OBD) -
DIAGNOSIS AND TESTING...............7-5
ONLY - ASSEMBLY, 5.9L................7-73
ONLY - DISASSEMBLY, 5.9L.............7-73
ON/OFF RELAY - DESCRIPTION, WIPER . . . 8R-25
ON/OFF RELAY - DIAGNOSIS AND
TESTING, WIPER.....................8R-26
ON/OFF RELAY - INSTALLATION, WIPER . . 8R-26
ON/OFF RELAY - OPERATION, WIPER....8R-25
ON/OFF RELAY - REMOVAL, WIPER......8R-26
ON/OFF SWITCH - DESCRIPTION,
PASSENGER AIRBAG.................8O-38
ON/OFF SWITCH - INSTALLATION,
PASSENGER AIRBAG.................8O-39
ON/OFF SWITCH - OPERATION,
PASSENGER AIRBAG.................8O-38
ON/OFF SWITCH - REMOVAL,
PASSENGER AIRBAG.................8O-39
OPEN-CIRCUIT VOLTAGE TEST -
STANDARD PROCEDURE...............8F-10
OPENING COVER - INSTALLATION,
STEERING COLUMN..................23-61
OPENING COVER - REMOVAL, STEERING
COLUMN...........................23-61
OPENING DIMENSIONS -
SPECIFICATIONS, BODY
...............23-99
OPENING SEAL - INSTALLATION, DOOR
. . . 23-92
OPENING SEAL - REMOVAL, DOOR
......23-92
OPENING SUPPORT BRACKET -
INSTALLATION, STEERING COLUMN
......23-62
OPENING SUPPORT BRACKET -
REMOVAL, STEERING COLUMN
.........23-61
OPERATING MODES, STANDARD
PROCEDURE - CONFIGURING A NEW
MODULE / SWITCH
....................8Q-3
ORDER / CABLE ROUTING, 5.7L V-8
ENGINE - FIRING
......................8I-4
ORDER, 3.7L V-6 - ENGINE FIRING
........8I-4
ORDER, 4.7L V-8 - ENGINE FIRING
........8I-4
ORDER, 5.9L V-8 - ENGINE FIRING
........8I-4
ORDER, 8.0L V-10 ENGINE - SPARK
PLUG CABLE
.........................8I-5
ORDER, DIESEL - FUEL INJECTOR
FIRING
.............................14-60
ORIFICE TUBE - DESCRIPTION, A/C
......24-48ORIFICE TUBE - DIAGNOSIS AND
TESTING, FIXED.....................24-48
ORIFICE TUBE - INSTALLATION, A/C......24-49
ORIFICE TUBE - OPERATION, A/C........24-48
ORIFICE TUBE - REMOVAL, A/C.........24-49
OUT INDICATOR - DESCRIPTION, LAMP . . . 8J-28
OUT INDICATOR - OPERATION, LAMP....8J-28
OUTBOARD - INSTALLATION, CENTER &
LEFT..............................8O-45
OUTBOARD - INSTALLATION, CENTER
ANCHOR & RIGHT...................8O-45
OUTBOARD - REMOVAL, CENTER & LEFT . 8O-43
OUTBOARD - REMOVAL, CENTER
ANCHOR & RIGHT...................8O-43
OUTBOARD SEAT BELT & RETRACTOR -
INSTALLATION, REAR.................8O-42
OUTBOARD SEAT BELT & RETRACTOR -
REMOVAL, REAR....................8O-41
OUTBOARD SEAT BELT BUCKLE -
INSTALLATION, FRONT................8O-34
OUTBOARD SEAT BELT BUCKLE -
REMOVAL, FRONT....................8O-33
OUTER BELT MOLDING - INSTALLATION,
FRONT DOOR.......................23-93
OUTER BELT MOLDING - INSTALLATION,
REAR DOOR........................23-94
OUTER BELT MOLDING - REMOVAL,
FRONT DOOR.......................23-93
OUTER BELT MOLDING - REMOVAL,
REAR DOOR........................23-94
OUTER TIE ROD END - DIAGNOSIS AND
TESTING.............................19-31
OUTER TIE ROD END - INSTALLATION....19-32
OUTER TIE ROD END - REMOVAL.......19-31
OUTLET - DESCRIPTION, CIGAR
LIGHTER.........................8W-97-2
OUTLET - DESCRIPTION, POWER......8W-97-7
OUTLET - DIAGNOSIS AND TESTING,
CIGAR LIGHTER...................8W-97-2
OUTLET - DIAGNOSIS AND TESTING,
POWER..........................8W-97-7
OUTLET - INSTALLATION, POWER.....8W-97-7
OUTLET - OPERATION, CIGAR LIGHTER . 8W-97-2
OUTLET - OPERATION, POWER.......8W-97-7
OUTLET - REMOVAL, POWER.........8W-97-7
OUTLETS - INSTALLATION, PANEL.......24-24
OUTLETS - REMOVAL, PANEL...........24-24
OUTPUT - DESCRIPTION, PCM...........8I-6
OUTPUT - OPERATION, PCM............14-32
OUTPUT - OPERATION, PCM.............8I-6
OUTPUT SHAFT FRONT BEARING -
INSTALLATION................21-217,21-395
OUTPUT SHAFT FRONT BEARING -
REMOVAL...................21-217,21-395
OUTPUT SHAFT REAR BEARING -
INSTALLATION................21-217,21-396
OUTPUT SHAFT REAR BEARING -
REMOVAL...................21-217,21-395
OUTPUT SHAFT SEAL - INSTALLATION,
FRONT..........21-618,21-653,21-683,21-717
OUTPUT SHAFT SEAL - REMOVAL,
FRONT..........21-617,21-653,21-683,21-717
OUTPUT SPEED SENSOR - DESCRIPTION . 21-567
OUTPUT SPEED SENSOR -
INSTALLATION......................21-567
OUTPUT SPEED SENSOR - OPERATION
. . 21-567
OUTPUT SPEED SENSOR - REMOVAL
. . . 21-567
OVERDRIVE CLUTCH - DESCRIPTION
. . . 21-218,
21-396
OVERDRIVE CLUTCH - OPERATION
.....21-218,
21-396
OVERDRIVE ELECTRICAL CONTROLS -
DIAGNOSIS AND TESTING
......21-219,21-397
OVERDRIVE OFF INDICATOR -
DESCRIPTION
.......................8J-33
OVERDRIVE OFF INDICATOR -
OPERATION
.........................8J-33
OVERDRIVE SWITCH - DESCRIPTION
. . . 21-218,
21-397,21-568
OVERDRIVE SWITCH - INSTALLATION
. . . 21-219,
21-397,21-569
OVERDRIVE SWITCH - OPERATION
.....21-218,
21-397,21-568
OVERDRIVE SWITCH - REMOVAL
......21-219,
21-397,21-568
OVERDRIVE UNIT - ASSEMBLY
. . . 21-228,21-406
OVERDRIVE UNIT - CLEANING
. . . 21-227,21-405
DRINDEX 23
Description Group-Page Description Group-Page Description Group-Page