Transfer Case - NV271: Removal & Installation Dodge Pickup R2500

REMOVAL

1. Raise and support vehicle.
2. Remove skid plate, if equipped. (Refer to «TRANSFER CASE SKID PLATE»(ref-189686-S35590418592005091100000) )
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. (Refer to «PROPELLER SHAFT»(ref-189646) )
10. Support transfer case with suitable jack. Secure transfer case to jack with safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission output shaft.
13. Lower jack and move transfer case from under vehicle.

INSTALLATION

1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with transmission output shaft. Align splines by rotating transfer case rear output shaft yoke if necessary. Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41 N.m (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to «PROPELLER SHAFT»(ref-189646) )
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fill plug.
9. Install skid plate, if equipped. (Refer to «TRANSFER CASE SKID PLATE»(ref-189686-S35590418592005091100000) )
10. Lower vehicle

1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the position sensor.
3. Remove the position sensor from the transfer case.

1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 20-34 N.m (15-25 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.

Scheme 126

1. Shift transfer case into 2H.
2. Raise and support the vehicle.
3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever.
4. Lower vehicle.
5. Remove transfer case shifter knob cap.
6. Remove nut holding shifter knob to shift lever.
7. Remove shifter knob.
8. Remove the shift boot from the shifter console.
9. Remove the bolts securing the shifter mechanism to the floor pan (Scheme 126)
10. Separate shift lever mechanism from the vehicle.

Scheme 127

1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the position (Scheme 127)
2. Position shift lever in vehicle.
3. Install the bolts to hold the shifter mechanism to the floor pan.
4. Raise vehicle.
5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward.
6. Install trunnion to shift lever, if necessary.
7. Install shift rod to trunnion, if necessary.
8. Tighten the shift rod lock bolt to 10 N.m (90 in.lbs.).
9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole.
10. Lower vehicle.
11. Install the transfer case shifter console.
12. Install the shifter boot and the shifter knob onto the shifter lever.
13. Install nut to hold shifter knob to shift lever.
14. Install shifter knob cap.
15. Verify transfer case operation.

Scheme 128

1. Move shift lever into 2H position.
2. Raise vehicle.
3. Loosen shift rod lock bolt at trunnion.
4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if necessary.
5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm is the second position from full forward.
6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly (Scheme 128)
7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position.
8. Tighten shift rod lock bolt to 10 N.m (90 in. lbs.) torque.
9. Remove the locating pin from the adjustment channel and locating hole.
10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges.