Transfer Case - NV271: 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 129

Scheme 130

Scheme 131

Scheme 132

1. Install two bolts 180° apart into the front output shaft companion flange.
2. Place holder over the bolts and against the companion flange (Scheme 129)
3. Remove and discard the front companion flange nut.
4. Remove the companion flange from the front output shaft. It may be necessary to use Flange puller 8992 to remove the companion flange.
5. Use a suitable chisel or pry tool to remove the rear extension housing dust boot (Scheme 130)
6. Use a suitable chisel or pry tool to remove the rear extension housing seal.
7. Remove rear extension bolts (Scheme 131)
8. Remove rear extension housing (Scheme 132) Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

1. Disengage the oil pump pick-up tube (Scheme 133) from the oil pump. NOTE: The oil pump pick-up tube seals to the oil pump with an o-ring. Verify that the o-ring was removed with the tube and is in good condition. Replace the o-ring if necessary.
2. Remove the oil pump (Scheme 134)
3. Remove rear case-to-front case bolts (Scheme 135)
4. Remove the rear output shaft bearing inner snap-ring (Scheme 136) from the output shaft using suitable snap-ring pliers.
5. Remove the rear output shaft bearing inner snap-ring (Scheme 137) from the output shaft.
6. Loosen rear case with pry tool to break sealer bead. Insert tool at each end of case (Scheme 138)
7. Unseat rear case from alignment dowels.
8. Remove the rear case from the front case (Scheme 139)

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

1. Remove the oil pick-up tube (Scheme 140) and screen from the front case half.
2. Remove the shift rail spring (Scheme 141)
3. Remove the front output shaft drive sprocket retaining ring (Scheme 142)
4. Remove the rear output shaft drive sprocket retaining ring (Scheme 143)
5. Pull front sprocket (Scheme 144), rear sprocket, and chain upward until clear of the front and rear output shaft sprocket splines.
6. Remove chain and sprockets as an assembly.

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever to sector shaft. Then remove shift lever (Scheme 145) and spacer from the shaft.
3. Remove the sector support with Socket 9033.
4. Remove the transfer case position sensor (Scheme 146)
5. Loosen detent plug (Scheme 147)
6. Remove detent plug, spring, and plunger (Scheme 148) Note that the plug has an O-ring seal. Remove and discard this seal.
7. Using a screw mounted in a slide hammer, remove the front output shaft seal.
8. Remove the front output shaft snap-ring (Scheme 149)
9. Remove front output shaft from bearing in case (Scheme 150)
10. Pull mainshaft assembly out of input gear, mode sleeve, and case (Scheme 151)
11. Remove mode fork, mode sleeve, and shift rail as assembly (Scheme 152) Note which way the sleeve fits in the fork (long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case).
12. Remove range fork and hub as an assembly (Scheme 153) Note fork position for installation reference.
13. Remove shift sector (Scheme 154)

Scheme 155

Scheme 156

Scheme 157

Scheme 158

1. Remove the clutch gear (Scheme 155) from the output shaft.
2. Remove the mode hub retaining ring (Scheme 156) from the mainshaft.
3. Remove the mode hub (Scheme 157) from the mainshaft.
4. Remove the drive sprocket drive hub (Scheme 158) from the mainshaft.

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (Scheme 159) 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 160) Tap gear out of bearing with plastic mallet, if necessary.
4. Remove snap-ring that retains input gear in the low range gear (Scheme 161)
5. Remove retainer (Scheme 162)
6. Remove front thrust plate (Scheme 163)
7. Remove input gear (Scheme 164)
8. Remove bottom tabbed thrust washer from low range planetary (Scheme 165)