Transfer Case - NV244 Transfer Case: Other Dodge Dakota III

OPERATING RANGES

NV244 operating ranges are

1. AWD (All-Wheel Drive)
2. 4HI (Part-time)
3. 4LO
4. NEUTRAL

The AWD mode can be used at any time and on any road surface.

The 4HI (Part-time) and 4LO ranges are for off road use only. The only time these ranges can be used is when the road surface is covered with snow, ice, or other loose slippery material.

SHIFT MECHANISM

Operating ranges are selected with a dash mounted shift selector switch. The shift selector switch provides a input to the Transfer Case Control Module (TCCM) to indicate the driver's desire to change operating ranges. The TCCM uses this input, along with the input from the transfer case mounted mode sensor and information from the vehicle's bus, to determine if a shift is permitted. If the TCCM decides the shift is permitted, the TCCM controls the shift motor, mounted to the exterior of the transfer case, to perform the shift.

Scheme 158

A circular ID tag (1) is attached to the rear case of each transfer case. The ID tag provides the transfer case model number, assembly number, serial number, and low range ratio. (Scheme 158)

The transfer case serial number also represents the date of build.

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 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.

The oil pickup screen can be cleaned with solvent. Shake excess solvent from the screen after cleaning and allow it to air dry. Do not use compressed air.

SHIFT FORKS/HUBS/SLEEVES

Check condition of the shift forks and mode fork shift rail. Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.

Inspect the shift fork wear pads. The mode and range fork pads are serviceable and can be replaced if necessary.

Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.

REAR RETAINER AND EXTENSION HOUSING

Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the bearing bore. Clean the retainer sealing surfaces with a scraper and 3M™ all purpose cleaner. This will ensure proper adhesion of the sealer during reassembly.

Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.

Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or damage.

FRONT OUTPUT SHAFT/FLANGE/DRIVE CHAIN

Check condition of the seal contact surfaces on the companion flange slinger. This surface must be clean and smooth to ensure proper seal life. Replace the flange nut and seal washer as neither part should be reused.

Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.

Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.

Scheme 159

Inspect annulus gear condition carefully. The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the gear (2). (Scheme 159)

FRONT/REAR CASES AND FRONT RETAINER

Inspect the cases and retainer for wear and damage. Replace the input retainer seal; do not reuse it.

Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil® stainless steel inserts if required.

OIL PUMP/OIL PICKUP

Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.

INPUT GEAR/LOW RANGE

Scheme 160

1. Assemble low range gear (2), input gear thrust washers (1), input gear (3) and input gear retainer (2). 1 - LOW RANGE GEAR SNAP RING
2. Install low range gear snap-ring (1). 1 - INPUT GEAR 2 - SNAP RING
3. Lubricate input gear and low range gears with automatic transmission fluid.
4. Start input gear shaft into front case bearing.
5. Press input gear (1) shaft into front bearing.
6. Install new input gear snap-ring (2). 1 - FRONT BEARING RETAINER
7. Apply 3 mm (1/8 in.) wide bead of Mopar® Gasket Maker, or equivalent silicone adhesive sealer, to seal surface of front bearing retainer (1).
8. Install front bearing retainer (1). Tighten retainer bolts to 16-25 N.m (12-18 ft. lbs.) torque.

SHIFT FORKS AND MAINSHAFT

Scheme 161

Scheme 162

Scheme 163

1. Install new sector shaft o-ring (2). 1 - RANGE HUB 2 - RANGE FORK
2. Install shift sector.
3. Install new pads on low range fork, if necessary.
4. Assemble low range fork and hub (1,2).
5. Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot. 1 - DIFFERENTIAL 2 - MAINSHAFT
6. Install bearing on mainshaft (2).
7. Install differential (1) 1 - DIFFERENTIAL SNAP RING
8. Install differential snap-ring (1). 1 - INTERMEDIATE CLUTCH SHAFT
9. Install intermediate clutch shaft (1). 1 - CLUTCH SHAFT THRUST RING
10. Install clutch shaft thrust ring (1) 1 - SNAP RING 2 - INTERMEDIATE CLUTCH SHAFT
11. Install clutch shaft snap-ring (1) 1 - SLIDER 2 - MODE FORK 3 - BUSHING/SPRING 4 - TUBE 5 - PADS
12. Inspect mode fork assembly. Replace pads and bushing (3) if necessary. Replace fork tube (4) if bushings inside tube are worn or damaged. Also check springs and slider bracket (1). Replace worn or damaged components. 1 - MAINSHAFT 2 - SLEEVE 3 - MODE FORK ASSEMBLY
13. Install mode sleeve (2) in mode fork (3). Then install assembled sleeve and fork on mainshaft (1). Be sure mode sleeve splines are engaged in differential splines. 1 - MAINSHAFT ASSEMBLY 2 - MODE FORK
14. Install mode fork and mainshaft assembly (1,2) in case. Rotate mainshaft (1) slightly to engage shaft with low range gears. 1 - SHIFT RAIL 2 - MODE FORK
15. Rotate mode fork pin into shift sector slot.
16. Install shift rail (1) with the taper to the rear of the transfer case. Be sure rail is seated in both shift forks. 1 - DETENT PLUNGER 2 - SEAL 3 - DETENT PLUG 4 - SPRING
17. Install detent plunger (1), detent spring (4), and detent plug (3) in case.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

1. Install front output shaft.
2. Install drive chain (2). Engage chain with front output shaft sprocket teeth.
3. Install drive sprocket (1). Engage drive sprocket teeth with chain (2). Then engage sprocket splines with mainshaft splines. 1 - DRIVE SPROCKET 2 - DRIVE SPROCKET SNAP RING
4. Install drive sprocket snap-ring (2).

Scheme 164

Scheme 165

1. Insert oil pickup tube (4) in oil pump and attach oil screen (2) and connector hose (3) to pickup tube. Then install assembled pump, tube and screen in rear case. Be sure screen is seated in case slot as shown in illustration. 1 - CASE MAGNET
2. Clean the transfer case magnet (1).
3. Install magnet in front case pocket.
4. Apply 3 mm (1/8 in.) wide bead of Mopar® Gasket Maker, or equivalent silicone adhesive sealer, to seal surface of front case.
5. Align and install rear case on front case. Be sure case locating dowels are in place and that mainshaft splines are engaged in oil pump inner gear.
6. Install and tighten front case to rear case bolts to 27-34 N.m (20-25 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.

REAR RETAINER

1. Apply bead of Mopar® Sealer, or Loctite™ Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 in.
2. Install rear retainer on rear case. Tighten retainer bolts to 27-34 N.m (20-25 ft. lbs.) torque.
3. Install new output shaft bearing snap-ring (2). Lift mainshaft slightly to seat snap-ring in shaft groove, if necessary.
4. Apply 3 mm (1/8 in.) wide bead of Mopar® Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of extension housing. Allow sealer to set-up slightly before proceeding.
5. Install extension housing on rear retainer.
6. Install extension housing bolts and tighten to 27-34 N.m (20-25 ft. lbs.).