Transfer Case - NV243: Overhaul Dodge Pickup R2500

DISASSEMBLY

Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

1. Remove the bolts (Scheme 241) which hold the shift motor and mode sensor assembly to the transfer case.
2. Remove the shift motor and mode sensor assembly from the transfer case.
3. Remove the front propeller shaft seal boot retaining clamp (Scheme 242)
4. Remove the front propeller shaft seal boot (Scheme 243)
5. Remove the front output shaft seal slinger by bending (Scheme 244) the slinger ears away from the transfer case.
6. Using a suitable pry tool (Scheme 245), remove the slinger from the output shaft using care not to damage the shaft.
7. Using a screw and a slide hammer, remove the front output shaft seal.

Scheme 246

Scheme 247

Scheme 248

1. Remove rear extension bolts (Scheme 246)
2. Remove rear extension housing (Scheme 247) Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.
3. Remove output bearing retaining ring with heavy duty snap-ring pliers (Scheme 248)

Scheme 249

Scheme 250

Scheme 251

1. Remove rear case-to-front case bolts (Scheme 249)
2. Loosen rear case with pry tool to break sealer bead. Insert tool in slot at each end of case (Scheme 250)
3. Unseat rear case from alignment dowels.
4. Remove rear case and oil pump assembly from front case (Scheme 251) CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump, the rear case and oil pump assembly MUST be replaced.
5. Remove the oil pump pickup tube.

Scheme 252

Scheme 253

Scheme 254

1. Remove shift rail cup and spring (Scheme 252)
2. Remove front sprocket retaining ring (Scheme 253)
3. Pull mainshaft, front sprocket and chain outward about 25.4 mm (1-inch) simultaneously (Scheme 254)
4. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

1. Loosen detent plug.
2. Remove detent plug, spring, and plunger (Scheme 255) Note that the plug has an O-ring seal. Remove and discard this seal.
3. Remove the front output shaft snap-ring (Scheme 256)
4. Remove front output shaft from bearing in case (Scheme 257)
5. Pull mainshaft assembly out of input gear, mode sleeve, and case (Scheme 258)
6. Remove mode fork, mode sleeve, and shift rail as assembly (Scheme 259) Note which way the sleeve fits in the fork (long side of sleeve goes to front).
7. Remove range fork retaining ring.
8. Remove range fork and hub as an assembly (Scheme 260) Note fork position for installation reference.
9. Remove shift sector (Scheme 261)
10. Remove the shift sector o-ring (Scheme 262)

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

1. Remove the drive sprocket retaining ring (Scheme 263) from the output shaft.
2. Remove the drive sprocket thrust washer (Scheme 264) from the output shaft.
3. Remove drive sprocket (Scheme 265) from the output shaft.
4. Remove the clutch gear (Scheme 266) and hub (Scheme 267) from the output shaft.
5. Remove the mode hub retaining ring (Scheme 268) from the output shaft.
6. Remove the mode hub (Scheme 269) from the output shaft.

Scheme 270

Scheme 271

1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (Scheme 270) with heavy duty snap-ring pliers.
3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Scheme 271) Tap gear out of bearing with plastic mallet, if necessary.

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

1. Remove snap-ring that retains input gear in low range gear (Scheme 272)
2. Remove retainer (Scheme 273)
3. Remove front tabbed thrust washer (Scheme 274)
4. Remove input gear (Scheme 275)
5. Remove rear tabbed thrust washer from low range gear (Scheme 276)

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

1. 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.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.
4. Position the shift motor and mode sensor assembly onto the transfer case.
5. Install the bolts to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-25 N.m (12-18 ft. lbs.).

Scheme 277

1. Install new seal in rear extension housing seal with Installer D-163 and Handle C-4171..
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into output bearing.
3. Align and install rear extension on retainer (Scheme 277)
4. Apply Mopar(R) Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts to 16-24 N.m (12-18 ft. lbs.) torque.