Overhaul - NV144: Removal & Installation Dodge Durango II

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 onto the transmission.
5. Install and tighten transfer case attaching nuts to 27-34 N.m (20-25 ft. lbs.) torque.
6. Connect the vent hose.
7. Connect the shift motor and mode sensor assembly wiring connector. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. (Refer to «PROPELLER SHAFT»(ref-212736) ).
9. Fill transfer case with correct fluid. (Refer to «FLUID»(ref-212832-S17365469092005122700000) )
10. Install skid plate, if equipped.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.

REMOVAL

1. Raise vehicle.
2. Remove rear propeller shaft. (Refer to «PROPELLER SHAFT»(ref-212736) )
3. Using a suitable pry tool or slide-hammer mounted screw, remove the rear case extension seal.

Scheme 80

1. Clean fluid residue from sealing surface and inspect for defects.
2. Using Installer D-163 (2) and Handle C-4171 (1), install the new seal into the rear case extension.
3. Install the rear propeller shaft. (Refer to «PROPELLER SHAFT»(ref-212736) )
4. Verify proper fluid level.
5. Lower vehicle.

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

Scheme 81

Scheme 82

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 (2) holding the shift motor and mode sensor assembly (1) onto the transfer case.
4. Separate the shift motor and mode sensor assembly (1) from the transfer case.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

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 shift motor assembly and the transfer case mating surface for sealing purposes. NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1) and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.
3. Position the shift motor and mode sensor assembly (1) onto the transfer case.
4. Install the bolts (2) to hold the assembly (1) onto the transfer case. Tighten the bolts to 9-14 N.m (7-10 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(tm) 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.