Dodge Ram Truck 1500-2500-3500. Manual — part 1872

FLUID

STANDARD PROCEDURE - FLUID DRAIN AND REFILL

The fill (1) and drain (2) plugs are both in the rear
case.

1. Raise vehicle.

2. Position drain pan under transfer case.

NOTE: It may be necessary to remove the exhaust
y-pipe at the exhaust manifold to properly access
the fill and drain plugs. Lowering the exhaust will
allow the plugs to be accessed for torquing during
installation. (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL)

3. Remove drain and fill plugs and drain lubricant

completely.

4. Install drain plug. Tighten plug to 41-54 N·m (30-40

ft. lbs.).

5. Remove drain pan.

6. Fill transfer case to bottom edge of fill plug opening

with Mopar

T

ATF +4, Automatic Transmission fluid.

7. Install and tighten fill plug to 41-54 N·m (30-40 ft. lbs.).

8. Install the exhaust y-pipe to the exhaust manifold, if removed. (Refer to 11 - EXHAUST SYSTEM/EXHAUST

PIPE - INSTALLATION)

9. Wipe any excess fluid that may have spilled onto the exhaust.

10. Lower vehicle.

SEAL-FRONT OUTPUT SHAFT

REMOVAL

1. Remove the front propeller shaft (Refer to 3 - DIF-

FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).

2. Install two bolts 180° apart into the front output

shaft companion flange.

3. Place Holder 6719 (1) over the bolts (2) and

against the companion flange.

4. Remove and discard the front companion flange

nut.

5. Remove the companion flange from the front out-

put shaft. It may be necessary to use Flange puller
8992 to remove the companion flange.

6. Using a screw and a slide hammer, remove the

front output shaft seal.

21 - 1420

TRANSFER CASE - NV271 - SERVICE INFORMATION

DR/DH

INSTALLATION

1. Install the new front output shaft seal with Installer

MB991168A.

2. Install the front companion flange onto the front

output shaft.

3. Install two bolts 180° apart into the front output

shaft companion flange.

4. Place Holder 6719 (1) over the bolts (2) and

against the companion flange.

5. Install a new front companion flange nut. Tighten

the companion flange nut to 258-312 N·m (190-230
ft.lbs.).

6. Install front propeller shaft (Refer to 3 - DIFFEREN-

TIAL &

DRIVELINE/PROPELLER

SHAFT/PRO-

PELLER SHAFT - INSTALLATION).

SENSOR-POSITION

DESCRIPTION

The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer
case’s current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a
specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sen-
sor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector
plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine
the sector plate, and therefore the transfer case, position.

OPERATION

Operating Mode Versus Resistance

SENSOR POSITION

OPERATING MODE

SENSOR RESISTANCE (ohms)

1

2H

1172-1195

2

4H

677-691

3

NEUTRAL

406-415

4

4L

208-213

5

NOT USED

60-61

DR/DH

TRANSFER CASE - NV271 - SERVICE INFORMATION

21 - 1421

During normal vehicle operation, the Powertrain Con-
trol Module (PCM) monitors the transfer case position
sensor return voltage to determine the operating mode
of the transfer case. Refer to the Operating Mode Ver-
sus Resistance table for the correct resistance for
each position.

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 connector to the position sensor.

4. Lower vehicle.

5. Verify proper sensor operation.

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

21 - 1422

TRANSFER CASE - NV271 - SERVICE INFORMATION

DR/DH

LEVER-SHIFT

REMOVAL

1. Shift transfer case into 2H.

2. Raise and support the vehicle.

3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of

trunnion, push trunnion out of shift lever.

4. Lower vehicle.

5. Remove transfer case shifter knob cap.

6. Remove nut holding shifter knob (2) to shift lever.

7. Remove shifter knob.

8. Remove the shift boot from the shifter console.

9. Remove the bolts securing the shifter mechanism to the floor pan.

10. Separate shift lever mechanism from the vehicle.

Transfer Case Shifter

1 - SHIFTER BOOT

4 - SHIFTER MECHANISM

2 - SHIFTER KNOB

5 - ALIGNMENT PIN

3 - SHIFTER CONSOLE

6 - TRANSFER CASE

DR/DH

TRANSFER CASE - NV271 - SERVICE INFORMATION

21 - 1423