Overhaul - NV242 Transfer Case: Removal & Installation

Overhaul - NV242 Transfer Case: Removal & Installation Dodge Durango I

Transfer Case 1 illustration ~342 words

Removal & Installation

Mark rear drive shaft and flange for reassembly reference. Remove rear drive shaft. Remove output shaft boot. Using a screwdriver, remove oil seal from extension housing. Using Remover (6957), remove bushing from rear retainer.
Position new bushing in rear retainer with fluid port aligned with slot in retainer. Drive bushing in with installer tool until installer seats against case. Coat NEW seal with petroleum jelly. Using seal protector and seal installer, drive seal in extension housing. Install boot on output shaft and crimp retaining clamp. To complete installation, reverse removal procedure.

Mark front drive shaft and flange for reassembly reference. Remove front drive shaft. Remove flange. Discard washer and nut. Using a screwdriver, carefully remove oil seal. Ensure seal contact surface is clean.
Apply ATF to seal lip and yoke seal surface. Install NEW oil seal using Installer (6952-A) and flange with NEW washer and nut. Install front drive shaft. Check transfer case fluid level. See «LUBRICATION»(ref-88514-S20190083722001022200000) .

Shift transfer case into 4WD position. Raise and support vehicle. Drain transfer case fluid. Remove rear crossmember and skid plate.
Mark front and rear drive shafts for reassembly reference. Remove front and rear drive shafts. Disconnect all electrical connections, vent hoses and shift linkage.
Using a hydraulic jack, support transfer case. Remove transfer case-to-transmission bolts. Separate transfer case from transmission. Remove transfer case. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-88514-S17025867842001022200000) .

Mark differential halves for reassembly purposes. Separate differential halves. Remove planetary gear and thrust washers. see scheme 6 Note mainshaft gear and sprocket gear position. Remove gears.
Lubricate differential components using ATF. Install drive sprocket gear in differential bottom case. Assemble differential planet gears and thrust washers. Ensure thrust washers are installed at top and bottom of each planet gear. Install mainshaft gear.
Using scribe marks made on disassembly, assemble differential case halves. While holding case halves together, invert differential. Install and tighten case bolts to specification. See «TORQUE SPECIFICATIONS»(ref-88514-S17025867842001022200000).