Transfer Case - NV244 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 80
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 81
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-247642-S35776982192007020100000).
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.

1. Install new front output seal in front case (2) with Installer Tool 8143-A (1) as follows: see scheme 99 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 136

1. Raise vehicle.
2. Remove rear propeller shaft. «Refer to REMOVAL»(ref-247643-S13692291362007020100000) .
3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal.
4. Using Remover 8158 (1), remove the bushing from rear retainer.

Scheme 137

Scheme 138

1. Clean fluid residue from sealing surface and inspect for defects.
2. Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer.
3. Using Installer 8157 (2), drive bushing (1) into retainer until installer seats against case. (Scheme 137) 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL D-163
4. Using Installer D-163 (2), install seal in rear retainer. (Scheme 138)
5. Install the rear propeller shaft. «Refer to INSTALLATION»(ref-247643-S00908099292007020100000).
6. Verify proper fluid level.
7. Lower vehicle.

Scheme 139

The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor, gear train, and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the mode and range forks found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4LOCK, AWD, N (neutral), and 4LO). The operating current of the shift motor under stall conditions is 30 amps maximum at 72°F with 13.5 volts, at the motor leads. (Scheme 139)

REMOVAL

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 105 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.