Transfer Case - NV243: Removal & Installation Dodge Pickup R2500

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 wiring connectors. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts.
9. Fill transfer case with correct fluid. (Refer to «STANDARD PROCEDURE - REFILL»(ref-189705-S34124702532005091100000) )
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 and support vehicle.
2. Remove rear propeller shaft. (Refer to «PROPELLER SHAFT»(ref-189646) )
3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal.
4. Using Remover 8158, remove bushing from extension housing.

Scheme 240

1. Clean fluid residue from sealing surface and inspect for defects.
2. Position replacement bushing in extension housing with fluid port in bushing aligned with slot in housing.
3. Using Installer 8157, drive bushing into housing until installer seats against case.
4. Using Installer D-163, install seal in extension housing (Scheme 240)
5. Install propeller shaft. (Refer to «PROPELLER SHAFT»(ref-189646) )
6. Verify proper transfer case fluid level.
7. Lower vehicle.

1. Install the new front output shaft seal with Installer MB991168A
2. 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.
3. Install a new seal boot clamp onto the seal boot.
4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.
5. Install front propeller shaft (Refer to «PROPELLER SHAFT»(ref-189646) ).

1. Raise the vehicle on a suitable hoist.
2. Disengage the wiring connectors from the shift motor and mode sensor.
3. Remove the bolts holding the shift motor and mode sensor assembly onto the transfer case.
4. Separate the shift motor and mode sensor assembly from the transfer case.

1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case.
2. Position the shift motor and mode sensor assembly onto the transfer case.
3. Install the bolts to hold the assembly onto the transfer case. Tighten the bolts to 16-24 N.m (12-18 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
4. Engage the wiring connectors to the shift motor and mode sensor.
5. Refill the transfer case as necessary.
6. Lower vehicle and verify transfer case operation.