Overhaul - NV144: Maintenance Dodge Durango II

STANDARD PROCEDURE - FLUID DRAIN AND REFILL

The fill and drain plugs (1, 3) are both in the rear case.

Scheme 146

1. Raise vehicle.
2. Position drain pan under transfer case.
3. Remove drain (3) and fill plugs (1) and drain lubricant completely.
4. Install drain plug (3). Tighten plug to 20-34 N.m (15-25 ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening with Mopar(R) ATF +4, Automatic Transmission fluid.
7. Install and tighten fill plug (1) to 20-34 N.m (15-25 ft.lbs.).
8. Lower vehicle.

Scheme 147

Scheme 148

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Scheme 151

Scheme 152

1. Remove the front propeller shaft (Refer to «PROPELLER SHAFT»(ref-212736) ).
2. Remove the front propeller shaft seal boot (1) retaining clamp (2).
3. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3).
4. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations.
5. The indentations (2) should appear as shown in illustration.
6. Remove the front output shaft seal slinger (1) from the output shaft (1).
7. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool.

Scheme 153

Scheme 154

Scheme 155

1. Install the new front output shaft seal (1) into position in the transfer case bore (2).
2. Install the new front output shaft seal (1) with Installer MB991168A.
3. Install the new front output shaft seal slinger (1) into position on the output shaft (2).
4. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
5. Install the seal boot (2) onto the seal slinger (3)
6. Install a new seal boot clamp onto the seal boot.
7. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.
8. Install the front propeller shaft (Refer to «PROPELLER SHAFT»(ref-212736) ).