NV243 Transfer Case - Service Information: Removal & Installation RAM Pickup 2500

INSTALLATION

1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case onto the transmission.
5. Install and tighten transfer case attaching nuts to 27-34 N.m (20-25 ft. lbs.) torque.
6. Connect the vent hose.
7. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. Refer to «SHAFT, Drive, Front Light Duty, Installation»(ref-457778-S21596541902012030200000) and «SHAFT, Drive, Rear Light Duty, Installation»(ref-457778-S10067659062012030200000) .
9. Fill transfer case with correct fluid. Refer to «STANDARD PROCEDURE - FLUID DRAIN AND REFILL»(ref-457854-S12136500542012030200000) .
10. Install skid plate, if equipped.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.

REMOVAL

Note. New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal.

1. Raise the vehicle on a suitable hoist.
2. Disengage the wiring connectors from the shift motor and mode sensor.
3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1).
4. Separate the shift motor and mode sensor assembly (2) from the transfer case.

1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case. NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned.
2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 N.m (12-18 ft. lbs.). CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar® Lock AND Seal or Loctite© 242 to replenish the lock patch material originally found on the bolts
4. Engage the wiring connectors to the shift motor and mode sensor.
5. Refill the transfer case as necessary.
6. Lower vehicle and verify transfer case operation.

1. Remove the front propeller shaft. Refer to «SHAFT, Drive, Front Light Duty, Removal»(ref-457778-S29911207512012030200000) and «SHAFT, Drive, Rear Light Duty, Removal»(ref-457778-S35273603822012030200000).
2. Remove the front propeller shaft seal boot (1) retaining clamp (2). see scheme 83 1 - SEAL BOOT 2 - SEAL SLINGER
3. Remove the front propeller shaft seal boot (1). see scheme 84 1 - SLINGER 2 - BEND UPWARD
4. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case. see scheme 85 1 - SLINGER 2 - PRY TOOL
5. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft. see scheme 86
6. Using a screw and a slide hammer, remove the front output shaft seal.

1. Install the new front output shaft seal with Seal Installer (special tool #MB-991168-A, Installer, Seal).
2. Install the front output shaft seal slinger with Oil Slinger Installer (special tool #8840, Installer, Oil Slinger). Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
3. Install a new seal boot clamp onto the seal boot.
4. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Axle Clamp Installer (special tool #C-4975A, Installer, Axle Clamp).
5. Install front propeller shaft. Refer to «SHAFT, Drive, Front Light Duty, Installation»(ref-457778-S21596541902012030200000) and «SHAFT, Drive, Rear Light Duty, Installation»(ref-457778-S10067659062012030200000) .

1. Raise and support vehicle.
2. Remove rear propeller shaft. Refer to «SHAFT, Drive, Front Light Duty , Removal»(ref-457778-S29911207512012030200000) and «SHAFT, Drive, Rear Light Duty , Removal»(ref-457778-S35273603822012030200000) .
3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal.

Scheme 6

1. Clean fluid residue from sealing surface and inspect for defects.
2. Using Seal Installer (special tool #D-163, Installer, Seal) (2) and Universal Handle (special tool #C-4171, Driver Handle, Universal) (1), install seal in extension housing. see scheme 87
3. Install propeller shaft. Refer to «SHAFT, Drive, Front Light Duty, Installation»(ref-457778-S21596541902012030200000) and «SHAFT, Drive, Rear Light Duty, Installation»(ref-457778-S10067659062012030200000).
4. Verify proper transfer case fluid level.
5. Lower vehicle.

Scheme 7

The transfer case mode sensor (1) is an electronic device whose output can be interpreted to indicate the shift motor shaft's rotary position. see scheme 88 The sensor consists of a magnetic ring and four Hall Effect Transistors to create a 4 channel digital device (non-contacting) whose output converts the motor shaft position into a coded signal. The Drive Train Control Module (DTCM) must supply 5VDC (+/- 0.5v) to the sensor and monitor the shift motor position. The four channels are denoted A, B, C, and D. The sensor is mechanically linked to the shaft of the cam which causes the transfer case shifting. The mode sensor draws less than 53 mA.