NV271 Transfer Case - Service Information: Component Locations RAM Cab & Chassis 3500 HD

SPECIAL TOOLS

6719A - Holder, Yoke (Originally Shipped In Kit Number(s) 6745, 6947, 6949, 9975.) 6953 - Remover/Installer, Bearing (Originally Shipped In Kit Number(s) 6945, 6947, 6949, 9975.) 7888 - Installer, Seal (Originally Shipped In Kit Number(s) 9975.) 8128 - Installer, Bearing (Originally Shipped In Kit Number(s) 8104, 9975.) 8148 - Cup (Originally Shipped In Kit Number(s) 8104, 9975.) 8151 - Installer, Bearing Cup (Originally Shipped In Kit Number(s) 8104.) 8152 - Installer, Seal (Originally Shipped In Kit Number(s) 8104, 9697, 9698.) 8891 - Installer, Seal (Originally Shipped In Kit Number(s) 8721, 8721CC, 8843, 9925, 9926.) 8992 - Remover, Pinion Flange (Originally Shipped In Kit Number(s) 8999, 8999CC, 9299, 9299CC, 9299CC, 9300A-CAN.) 9033 - Socket, Sector Support (Originally Shipped In Kit Number(s) 8848, 8849, 8849CC.) 9035 - Installer, Bearing (Originally Shipped In Kit Number(s) 8848, 8849, 8849CC.) 9036 - Installer, Seal (Originally Shipped In Kit Number(s) 8848, 8849, 8849CC.) 9037 - Installer, Dust Boot/Seal (Originally Shipped In Kit Number(s) 8848, 8849, 8849CC.) C-4171 - Driver Handle, Universal (Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299, 9299CC, 9299CC, 9300A-CAN.) L-4454A - Remover, Bearing Cup (Originally Shipped In Kit Number(s) 9975.) MB-991168-A - Installer, Seal (Originally Shipped In Kit Number(s) 8847, 8853, 8854, 8854CC, 9975.)

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

The fill (1) and drain (2) plugs are both in the rear case. (Scheme 41)

1. Raise vehicle.
2. Position drain pan under transfer case. NOTE: It may be necessary to remove the exhaust y-pipe at the exhaust manifold to properly access the fill and drain plugs. Lowering the exhaust will allow the plugs to be accessed for torquing during installation. Refer to «PIPE, EXHAUST, REMOVAL»(ref-476515-S31721959422012060400000) .
3. Remove drain and fill plugs and drain lubricant completely.
4. Install drain plug. Tighten plug to 20-34 N.m (15-25 ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening with Mopar® ATF +4, Automatic Transmission fluid.
7. Install and tighten fill plug to 20-34 N.m (15-25 ft. lbs.).
8. Install the exhaust y-pipe to the exhaust manifold, if removed. Refer to «PIPE, EXHAUST, INSTALLATION»(ref-476515-S15068440442012060400000) .
9. Wipe any excess fluid that may have spilled onto the exhaust.
10. Lower vehicle.

Scheme 47

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 42)
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.