Transfer Case - NV243: Overview Dodge Pickup R1500

DESCRIPTION

The NV243 is an electronically controlled part-time transfer case with a low range gear reduction system. The NV243 has three operating ranges plus a NEUTRAL position. The low range system provides a gear reduction ratio for increased low speed torque capability.

The geartrain is mounted in two aluminum case halves attached with bolts. The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves.

IDENTIFICATION

A circular ID tag is attached to the rear case of each transfer case (Scheme 233) The ID tag provides the transfer case model number, assembly number, serial number, and low range ratio.

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

Scheme 233

OPERATION

The input gear is splined to the transmission output shaft. The input gear drives the mainshaft through the planetary assembly and range sleeve. The front output shaft is operated by a drive chain that connects the shaft to a drive sprocket on the mainshaft. The drive sprocket is engaged/disengaged by the mode fork, which operates the mode sleeve and hub. The sleeve and hub are not equipped with a synchronizer mechanism for shifting.

Scheme 234

Scheme 235

Scheme 236

1. Shift transfer case into 2WD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at transfer case.
8. Disconnect transfer case shift motor and mode sensor wire connectors.
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case to transmission (Scheme 236)
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove transfer case from under vehicle.

The transfer case mode sensor (Scheme 237) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The TCCM must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA.

Scheme 237

During normal vehicle operation, the Transfer Case Control Module (TCCM) monitors the mode sensor outputs at least every 250 (+/-50) milliseconds when the shift motor is stationary and 400 microseconds when the shift motor is active. A mode sensor signal between 3.8 Volts and 0.8 Volts is considered to be undefined.

Refer to SECTOR ANGLES vs. TRANSFER CASE POSITION for the relative angles of the transfer case shift sector versus the interpreted transfer case gear operating mode. Refer to MODE SENSOR CHANNEL STATES for the sensor codes returned to the TCCM for each transfer case mode sensor position. The various between gears positions can also be referred as the transfer case's coarse position. These coarse positions come into play during shift attempts.

SECTOR ANGLES VS TRANSFER CASE POSITION

MODE SENSOR CHANNEL STATES

The selector switch assembly (Scheme 238) is mounted in the left side of the vehicle's Instrument Panel (IP) and consists of a rotary knob connected to a resistive network for the mode and range shift selections. Also located in this assembly is a recessed, normally open momentary switch for making shifts into and out of transfer case NEUTRAL. A pen, or similar instrument, is used to make a NEUTRAL shift selection, thus reducing the likelihood of an inadvertent shift request.

The selector switch also contains four light emitting diode's (LED's) to indicate the transfer case position and whether a shift is in progress.

Scheme 238

As the position of the selector switch varies, the resistance between the Mode Sensor supply voltage pin and the Mode Sensor output will vary. Hardware, software, and calibrations within the Transfer Case Control Module (TCCM) are provided that interpret the selector switch resistance as given in the SELECTOR SWITCH INTERPRETATION table

SELECTOR SWITCH INTERPRETATION

For resistances between the ranges B-E shown for each valid position (T-Case NEUTRAL, 4LO, 4HI, 2WD), the TCCM may interpret the resistance as

1. either of the neighboring valid positions.
2. as an invalid fault position.

For resistances between the ranges E and F shown for 2WD and in-between positions, the TCCM may interpret the resistance as

1. the 2WD position.
2. an invalid fault position.
3. a valid in-between position.

For resistances between the ranges F and G shown for in-between positions and fault condition (open), the TCCM may interpret the resistance as

1. a valid in-between position.
2. an invalid fault position.

For resistances between the ranges A and B shown for the fault condition (short) and, T-Case NEUTRAL, the TCCM may interpret the resistance as

1. the T-Case NEUTRAL position.
2. an invalid fault position.

The LED's in the selector assembly are illuminated/flashed in the following manner to indicate a particular condition or state.

1. A solidly illuminated LED indicates a successfully completed shift and the current operating mode of the transfer case. While a shift has been requested but not yet completed, the LED for the desired transfer case position is flashed.
2. A flashing operating mode LED for the desired gear indicates that a shift to that position has been requested, but all of the driver controllable conditions have not been met. This is in an attempt to notify the driver that the transmission needs to be put into NEUTRAL, the vehicle speed is too great, or some other condition outlined (other than a diagnostic failure that would prevent this shift) elsewhere (Refer to «TRANSMISSION CONTROL MODULE»(ref-189660-S00879424792005091200000) ) is not met. Note that this flashing will continue indefinitely until the conditions are eventually met, or the selector switch position is changed, or if diagnostic routines no longer allow the requested shift.
3. If the driver attempts to make a shift into transfer case NEUTRAL, and any of the driver controllable conditions are not met, the request will be ignored until all of the conditions are met or until the NEUTRAL select button is released. Additionally the neutral lamp will flash, or begin to flash while the button is depressed and operator controllable conditions are not being met. All of the LED's except the Neutral will flash if any of the operator controllable conditions for shifting are not met while the Neutral button is depressed. This "toggle" type of feature is necessary because the TCCM would interpret another request immediately after the shift into transfer case NEUTRAL has completed.
4. No LED's illuminated indicate a fault in the transfer case control system.

The shift motor (Scheme 239) consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low torque device into a low speed-high torque device. The output of the device is coupled to a shaft which internally moves the mode and range forks that change the transfer case operating ranges. The motor is rated at 25 amps maximum at 72°F with 10 volts at the motor leads.

Scheme 239

The transfer case shift motor responds to the Transfer Case Control Module (TCCM) commands to move the transfer case shift sector bi-directionally, as required, to obtain the transfer case operating mode indicated by the instrument panel mounted selector switch.