Transfer Case - NV233 Transfer Case: Overhaul Dodge Dakota III

DISASSEMBLY

Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Remove extension housing bolts.
2. Tap extension housing (1) with plastic or rawhide mallet (2) to loosen sealer. (Scheme 24) 1 - REAR RETAINER 2 - SNAP-RING 3 - REAR OUTPUT SHAFT BEARING
3. Separate extension housing from rear retainer.
4. Remove rear bearing snap-ring. (Scheme 25) 1 - REAR RETAINER 2 - RETAINER BOSS 3 - PRY TOOL 4 - SHIFT RAIL
5. Remove bolts holding rear retainer to rear case half.
6. Loosen rear retainer (1) with pry tool (3) to break sealer bead. Pry only against retainer boss as shown in the illustration. (Scheme 26) 1 - OIL PUMP
7. Disengage oil pickup tube from oil pump (1) and remove oil pump assembly. (Scheme 27) 1 - OIL PUMP 2 - O-RING
8. Remove pick-up tube o-ring (2) from oil pump (1), if necessary. Do not disassemble the oil pump, it is not serviceable. (Scheme 28)

Scheme 29

1. Remove front companion flange nut with a socket and impact wrench
2. Remove the front companion flange. If the flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned on the flange and not on the slinger, as slinger will be damaged.
3. Remove seal washer from front output shaft. Discard washer as it should not be reused.
4. Remove the bolts (3) which hold the shift motor and mode sensor assembly (2) to the transfer case (1). (Scheme 29)
5. Remove the shift motor and mode sensor assembly from the transfer case.

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Support transfer case so rear case is facing upward.
2. Remove bolts holding front case to rear case. The case alignment bolts require flat (1). (Scheme 30) 1 - REAR CASE 2 - PRY TOOL (IN CASE SLOT) 3 - FRONT CASE
3. Loosen rear case (1) with flat blade screwdriver (2) to break sealer bead. Insert pry tool blade only into notches provided at each end of case. (Scheme 31)
4. Remove rear case from front case. 1 - HOSE 2 - PICK-UP SCREEN 3 - PICK-UP TUBE
5. Remove oil pickup tube (3) from rear case. (Scheme 32) 1 - MODE SPRING
6. Remove mode fork spring (1). (Scheme 33) 1 - DRIVE CHAIN 2 - FRONT OUTPUT SHAFT 3 - SHAFT FRONT BEARING
7. Pull front output shaft (2) upward and out of front output shaft bearing (3). (Scheme 34)
8. Remove front output shaft (2) and chain (1).

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Remove detent plug (3), O-ring (2), detent spring (4), and detent plunger (1). (Scheme 35) 1 - MODE SLEEVE 2 - MODE FORK AND RAIL
2. Remove mainshaft from mode sleeve and input gear pilot bearing.
3. Remove mode fork (2) and sleeve (1) as an assembly. Note position of sleeve for assembly reference. The short side of the sleeve faces upward. (Scheme 36) 1 - RANGE HUB 2 - RANGE FORK
4. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference. (Scheme 37) 1 - SHIFT SECTOR
5. Remove shift sector (1) from front case. (Scheme 38) 1 - FRONT HOUSING 2 - O-RING
6. Remove shift sector O-ring (2). (Scheme 39)

Scheme 40

Scheme 41

Scheme 42

1. Remove mode hub (1) retaining ring (3) with heavy duty snap-ring pliers (2). (Scheme 40) 1 - MAINSHAFT 2 - MODE HUB
2. Slide mode hub (2) off mainshaft (1). (Scheme 41) 1 - DRIVE SPROCKET 2 - MAINSHAFT
3. Slide drive sprocket (1) off mainshaft (2). (Scheme 42)

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Remove front bearing retainer (2) attaching bolts (3). (Scheme 43) 1 - FRONT BEARING RETAINER 2 - PRY SLOT
2. Remove front bearing retainer. Pry retainer (1) loose with pry tool positioned in slots (2) at each end of retainer. (Scheme 44) 1 - INPUT GEAR BEARING RETAINING RING 2 - INPUT GEAR BEARING 3 - SNAP-RING PLIERS
3. Remove front bearing retainer seal. Tap seal out with drift and hammer.
4. Remove input gear retaining ring (1) with heavy duty snap-ring pliers (3). (Scheme 45)1 - INPUT AND LOW RANGE GEAR ASSEMBLY
5. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (1). (Scheme 46) Tap gear out of bearing with plastic mallet if necessary.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Remove snap-ring (1) that retains input gear in low range gear. (Scheme 47) 1 - INPUT GEAR 2 - LOW RANGE GEAR 3 - RETAINER
2. Remove retainer (3) from the low range gear. (Scheme 48) 1 - FRONT TABBED THRUST WASHER
3. Remove front tabbed thrust washer (1). (Scheme 49) 1 - INPUT GEAR 2 - LOW RANGE GEAR
4. Remove input gear (1). (Scheme 50) 1 - LOW RANGE GEAR 2 - REAR TABBED THRUST WASHER
5. Remove rear tabbed thrust washer from low range gear. (Scheme 51)

ASSEMBLY

Lubricate transfer case components with Mopar® ATF +4, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly.

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

1. Remove the front output shaft seal (1) from case with pry tool (2). (Scheme 52) 1 - SCREWDRIVERS 2 - SNAP-RING 3 - FRONT OUTPUT SHAFT BEARING 4 - FRONT CASE
2. Remove bearing retaining ring with screwdriver. (Scheme 53) 1 - FRONT CASE 2 - SPECIAL TOOL C-4171 3 - SPECIAL TOOL 5065
3. Remove bearing with Tool Handle C-4171 (2) and Tool 5065 (3). (Scheme 54) 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 5064
4. Install front output shaft front bearing in case with Tool Handle C-4171 (1) and Installer 5064 (2). (Scheme 55) 1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL SCREWDRIVER
5. Install output shaft front bearing retaining ring (1). (Scheme 56) Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding. 1 - INSTALLER 8143-A 2 - TRANSFER CASE
6. Install new front output seal in front case with Installer Tool 8143-A (1) as follows: (Scheme 57) Place new seal on tool. Garter spring on seal goes toward interior of case. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool bottoms against case. 1 - FRONT HOUSING 2 - REMOVER L-4454 3 - CUP 8148
7. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3). (Scheme 58) 1 - HANDLE C-4171 2 - BEARING 3 - INSTALLER 5066
8. Install new bearing with Tool Handle C-4171 (1) and Installer 5066 (3). (Scheme 59) 1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER 2 - CHAMFER
9. The bearing bore is chamfered at the top. Install the bearing (1) so it is flush with the lower edge of this chamfer (2). (Scheme 60) 1 - HANDLE C-4171 2 - INSTALLER C-4210
10. Using Remover C-4210 (2) and Handle C-4171 (1), drive input shaft bearing from inside the annulus gear opening in the case. (Scheme 61) 1 - SNAP RING 2 - INPUT SHAFT BEARING
11. Install locating ring on new bearing.
12. Position case so forward end is facing upward.
13. Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring (1) must be fully seated against case surface. (Scheme 62) 1 - DRIFT 2 - INPUT GEAR
14. Remove input gear pilot bearing by inserting a suitably sized drift (1) into the splined end of the input gear (2) and driving the bearing out with the drift and a hammer. (Scheme 63) 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 5065 3 - INPUT GEAR
15. Install new pilot bearing with Installer 5065 (2) and Handle C-4171 (1). (Scheme 64) 1 - FRONT BEARING RETAINER 2 - TOOL 7884
16. Remove front bearing retainer seal with suitable pry tool.
17. Install new front bearing retainer (1) with Installer 7884 (2). (Scheme 65) 1 - HOUSING SEAL 2 - SPECIAL TOOL 7888 3 - OIL PUMP FEED HOUSING
18. Remove seal from oil pump housing with a suitable pry tool
19. Install new seal (1) in oil pump housing (3) with Installer 7888 (2). (Scheme 66) 1 - TOOL C-4171 2 - TOOL 5064 3 - REAR RETAINER
20. Remove rear retainer bearing with Installer 5065 and Handle C-4171.
21. Install rear bearing in retainer (3) with Handle C-4171 (1) and Installer 5064 (2). (Scheme 67)

Scheme 68

1. Lubricate gears (3, 4) and thrust washers (5) with recommended transmission fluid. (Scheme 68)
2. Install first thrust washer (5) in low range gear (4). Be sure washer tabs are properly aligned in gear notches.
3. Install input gear (3) in low range gear (4). Be sure input gear is fully seated.
4. Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
5. Install retainer on input gear and install snap-ring.

Scheme 69

Scheme 70

Scheme 71

1. Align and install low range/input gear assembly (2) in front case. Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing. (Scheme 69) 1 - INPUT GEAR 2 - SNAP-RING
2. Install snap-ring (2) to hold input/low range gear (1) into front bearing. (Scheme 70) 1 - FRONT BEARING RETAINER
3. Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
4. Apply a 3 mm (1/8 in.) bead of Mopar® Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer.
5. Align cavity in seal retainer with fluid return hole in front of case. CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying Mopar® Gasket Maker, or equivalent silicone adhesive sealer. Seal failure and fluid leak can result.
6. Install bolts to hold retainer (1) to transfer case. Tighten to 16-25 N.m (12-18 ft. lbs.) of torque. (Scheme 71)

COMPANION FLANGE AND SHIFT MOTOR AND MODE SENSOR ASSEMBLY

Scheme 72

1. Position the shift motor and mode sensor assembly (2) onto the transfer case. see scheme 70
2. Install the bolts (3) to hold the shift motor and mode sensor assembly (2) to the transfer case (1). Tighten the bolts to 16-25 N.m (12-18 ft. lbs.) torque. 1 - SEAL WASHER
3. Install new seal washer (1) onto the front output shaft. (Scheme 72)
4. Lubricate the companion flange hub with transmission fluid and install the flange onto the front output shaft.
5. Install a new companion flange nut onto the front output shaft.
6. Tighten the flange nut to 122-176 N.m (90-130 ft. lbs.) torque. Use Tool 6958, or similar tool to hold flange while tightening nut.