NV243 Transfer Case - Service Information: Overhaul RAM Pickup 2500

DISASSEMBLY

Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.

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1. Remove the bolts (3) which hold the shift motor and mode sensor assembly (2) to the transfer case (1). 1 - SEAL BOOT 2 - BOOT CLAMP
2. Remove the shift motor and mode sensor assembly from the transfer case.
3. Remove the front propeller shaft seal boot (1) retaining clamp (2). (Scheme 9) 1 - SEAL BOOT 2 - SEAL SLINGER
4. Remove the front propeller shaft seal boot (1). (Scheme 10) 1 - SLINGER 2 - BEND UPWARD
5. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. (Scheme 11) 1 - SLINGER 2 - PRY TOOL
6. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. (Scheme 12)
7. Using a screw and a slide hammer, remove the front output shaft seal.

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1. Remove rear extension bolts (1). (Scheme 13) 1 - EXTENSION HOUSING 2 - TRANSFER CASE 3 - PRY SLOT
2. Remove rear extension housing (1). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it. 1 - REAR OUTPUT SHAFT 2 - OUTPUT SHAFT BEARING 3 - RETAINING RING 4 - TRANSFER CASE
3. Remove output bearing (2) retaining ring (3) with heavy duty snap-ring pliers.

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1. Remove rear case (1)-to-front case (2) bolts (3). 1 - REAR CASE 2 - FRONT CASE 3 - PRY SLOTS
2. Loosen rear case (1) with pry tool to break sealer bead. Insert tool in slot (3) at each end of case. 1 - REAR CASE 2 - FRONT CASE
3. Unseat rear case from alignment dowels.
4. Remove rear case (1) and oil pump assembly from front case (2). CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.
5. Remove the oil pump pickup tube.

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1. Remove shift rail cup (3) and spring (2). 1 - FRONT SPROCKET 2 - RETAINING RING 3 - FRONT OUTPUT SHAFT
2. Remove front sprocket (1) retaining ring (2). 1 - FRONT DRIVE SPROCKET 2 - DRIVE CHAIN 3 - MAINSHAFT
3. Pull mainshaft (3), front sprocket (1), and chain (2) outward about 25 mm (1 inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.

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1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal. 1 - FRONT OUTPUT SHAFT 2 - SNAP-RING
3. Remove the front output shaft (1) snap-ring (2). 1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
4. Remove front output shaft (2) from bearing in the front case (1). 1 - FRONT CASE 2 - MAINSHAFT
5. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1). 1 - MODE SLEEVE 2 - MODE FORK AND RAIL
6. Remove mode fork (2), mode sleeve (1), and shift rail as assembly. Note which way the sleeve fits in the fork (long side of sleeve goes to front). 1 - RANGE HUB 2 - RANGE FORK
7. Remove range fork retaining ring.
8. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference. 1 - SHIFT SECTOR
9. Remove shift sector (1). 1 - TRANSFER CASE FRONT HOUSING 2 - SHIFT SECTOR O-RING
10. Remove the shift sector o-ring (2) from the front housing (1).

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1. Remove the drive sprocket (3) retaining ring (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - THRUST WASHER 3 - DRIVE SPROCKET
2. Remove the drive sprocket (3) thrust washer (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - DRIVE SPROCKET
3. Remove drive sprocket (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - CLUTCH GEAR 3 - MODE HUB
4. Remove the clutch gear (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - SPROCKET HUB
5. Remove the sprocket hub (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - RETAINING RING 3 - MODE HUB
6. Remove the mode hub retaining ring (2) from the output shaft (1). 1 - OUTPUT SHAFT 2 - MODE HUB
7. Remove the mode hub (2) from the output shaft (1).

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1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear (1) retaining ring (2) with heavy duty snap-ring pliers. 1 - FRONT CASE 2 - INPUT PLANETARY ASSEMBLY
3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.

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1. Remove snap-ring (1) that retains input gear in low range gear. 1 - INPUT GEAR 2 - LOW RANGE GEAR 3 - RETAINER
2. Remove retainer (3). 1 - FRONT TABBED THRUST WASHER
3. Remove front tabbed thrust washer (1). 1 - INPUT GEAR 2 - LOW RANGE GEAR
4. Remove input gear (1). 1 - LOW RANGE GEAR 2 - REAR TABBED THRUST WASHER
5. Remove rear tabbed thrust washer (2) from low range gear (1).

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

1. Install the front output shaft seal slinger with Installer (special tool #8840, Installer, Oil Slinger). Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool (special tool #C-4975A, Installer, Axle Clamp). 1 - TRANSFER CASE 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 3 - BOLT
4. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
5. Install the bolts (3) to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-24 N.m (12-18 ft. lbs.).