Transfer Case - NV273: 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 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

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 341)
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 342)
6. Use a suitable chisel or pry tool to remove the rear extension housing seal.
7. Remove rear extension bolts (Scheme 343)
8. Remove rear extension housing (Scheme 344) Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

1. Disengage the oil pump pick-up tube (Scheme 345) 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 346)
3. Remove rear case-to-front case bolts (Scheme 347)
4. Remove the rear output shaft bearing inner snap-ring (Scheme 348) from the output shaft using suitable snap-ring pliers.
5. Remove the rear output shaft bearing inner snap-ring (Scheme 349) from the output shaft.
6. Loosen rear case with pry tool to break sealer bead. Insert tool at each end of case (Scheme 350)
7. Unseat rear case from alignment dowels.
8. Remove the rear case from the front case (Scheme 351)

Scheme 352

Scheme 353

Scheme 354

Scheme 355

1. Remove the oil pick-up tube (Scheme 352) and screen from the front case half.
2. Remove the front output shaft drive sprocket retaining ring (Scheme 353)
3. Remove the rear output shaft drive sprocket retaining ring (Scheme 354)
4. Pull front sprocket (Scheme 355), rear sprocket, and chain upward until clear of the front and rear output shaft sprocket splines.
5. Remove chain and sprockets as an assembly.

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

1. Remove the bolts (Scheme 356) that hold the shift motor assembly to the transfer case.
2. Remove the shift motor assembly (Scheme 357) from the transfer case.
3. Remove the sector support with Socket 9033.
4. Loosen detent plug (Scheme 358)
5. Remove detent plug, spring, and plunger (Scheme 359) Note that the plug has an O-ring seal. Remove and discard this seal.
6. Using a screw mounted in a slide hammer, remove the front output shaft seal.
7. Remove the front output shaft snap-ring (Scheme 360)
8. Remove front output shaft from bearing in case (Scheme 361)
9. Pull mainshaft assembly out of input gear, mode sleeve, and case (Scheme 362)
10. Remove mode fork, mode sleeve, and shift rail as assembly (Scheme 363) 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).
11. Remove range fork and hub as an assembly (Scheme 364) Note fork position for installation reference.
12. Remove the shift sector (Scheme 365)

Scheme 366

Scheme 367

Scheme 368

Scheme 369

1. Remove the clutch gear (Scheme 366) from the output shaft.
2. Remove the mode hub retaining ring (Scheme 367) from the mainshaft.
3. Remove the mode hub (Scheme 368) from the mainshaft.
4. Remove the drive sprocket drive hub (Scheme 369) from the mainshaft.

Scheme 370

Scheme 371

Scheme 372

Scheme 373

Scheme 374

Scheme 375

1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (Scheme 370) 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 371) Tap gear out of bearing with plastic mallet, if necessary.
4. Remove snap-ring that retains input gear in the low range gear (Scheme 372)
5. Remove retainer (Scheme 373)
6. Remove front thrust plate (Scheme 374)
7. Remove input gear (Scheme 375)
8. Remove bottom tabbed thrust washer from low range planetary see scheme 40