Transfer Case - NV233 Transfer Case: Removal & Installation Dodge Dakota III

INSTALLATION

1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case (2) onto the transmission (1). see scheme 73
5. Install and tighten transfer case attaching nuts (3) to 27-34 N.m (20-25 ft. lbs.) torque. 1 - TRANSMISSION 2 - VENT HOSE 3 - TRANSFER CASE 4 - WIRING CONNECTOR
6. Connect the vent hose (2) to the transfer case (3). see scheme 74
7. Connect the shift motor and mode sensor wiring connectors (4). Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. «(Refer to INSTALLATION)»(ref-247643-S00908099292007020100000)
9. Fill transfer case with correct fluid. «(Refer to STANDARD PROCEDURE)»(ref-247641-S05764155512007020100000)
10. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 41 N.m (30 ft. lbs.) torque.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.

REMOVAL

1. Raise vehicle.
2. Remove front propeller shaft. «(Refer to REMOVAL)»(ref-247643-S13692291362007020100000)
3. Remove front output shaft companion flange.
4. Remove seal (1) from front case with suitable pry tool. see scheme 90

1. Install new front output seal in front case (2) with Installer Tool 8143-A (1) as follows: see scheme 91 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 seats against case.
2. Install the front output shaft companion flange. Tighten the flange nut to 122-176 N.m (90-130 ft. lbs.).
3. Install the front propeller shaft. «(Refer to INSTALLATION)»(ref-247643-S00908099292007020100000)

Scheme 23

The transfer case mode sensor (1) provides the Front Control Module (FCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The FCM must supply 5V DC (+/- 0.5v) to the sensor whenever the FCM is not in sleep mode and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is shifted to the OFF position. The sensor is mechanically linked to the shaft of the cam which allows the transfer case to shift. The mode sensor will draw less than 20 mA of current during operation. (Scheme 23)

Note. New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor installation.

1. Raise the vehicle on a suitable hoist.
2. Disengage the wiring connector from the shift motor and mode sensor assembly.
3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1).
4. Separate the shift motor and mode sensor assembly (2) from the transfer case (1).

1. Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.
2. Add high temperature grease between the actuator and the transfer case mating surface for sealing purposes. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned.
3. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
4. Install the bolts (3) to hold the assembly (2) onto the transfer case (1). Tighten the bolts to 16-24 N.m (12-18 ft.lbs.). see scheme 98 CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar® Lock & Seal or Loctite™ 242 to replenish the lock patch material originally found on the bolts
5. Engage the wiring connector to the shift motor and mode sensor assembly.
6. Refill the transfer case as necessary.
7. Lower vehicle and verify transfer case operation.