NV271 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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Scheme 71

1. Install two bolts 180° apart into the front output shaft companion flange.
2. Place holder (1) over the bolts (2) and against the companion flange. (Scheme 68)
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 Pinion Flange Remover (special tool #8992, Remover, Pinion Flange) to remove the companion flange. 1 - EXTENSION HOUSING 2 - DUST BOOT
5. Use a suitable chisel or pry tool to remove the rear extension housing (1) dust boot (2). (Scheme 69)
6. Use a suitable chisel or pry tool to remove the rear extension housing seal. 1 - EXTENSION HOUSING 2 - BOLTS
7. Remove rear extension (1) bolts (2). (Scheme 70) 1 - REAR CASE HALF 2 - EXTENSION HOUSING
8. Remove rear extension housing (2) from the rear case half. (Scheme 71) Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.

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1. Disengage the oil pump pick-up tube (2) from the oil pump (1). (Scheme 72) 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. 1 - REAR CASE HALF 2 - REAR OUTPUT SHAFT 3 - OIL PUMP
2. Remove the oil pump (3) from the rear output shaft (2). (Scheme 73) 1 - FRONT CASE HALF 2 - REAR CASE HALF 3 - BOLTS
3. Remove rear case (2)-to-front case (1) bolts (3). (Scheme 74) 1 - OUTPUT SHAFT 2 - REAR CASE HALF 3 - SNAP-RING
4. Remove the rear output shaft bearing inner snap-ring (3) from the output shaft (1) using suitable snap-ring pliers. (Scheme 75) 1 - OUTPUT SHAFT 2 - REAR CASE HALF 3 - SNAP-RING
5. Remove the rear output shaft bearing inner snap-ring (3) from the output shaft (1). (Scheme 76) 1 - FRONT CASE HALF 2 - REAR CASE HALF
6. Loosen rear case (2) with pry tool to break sealer bead. Insert tool at each end of case. (Scheme 77) 1 - FRONT CASE HALF 2 - REAR CASE HALF
7. Unseat rear case from alignment dowels.
8. Remove the rear case (2) from the front case (1). (Scheme 78)

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Scheme 83

1. Remove the oil pick-up tube (3) and screen (2) from the front case half (1). (Scheme 79) 1 - SHIFT RAIL 2 - SPRING
2. Remove the shift rail spring (2) from the shift rail (1). (Scheme 80) 1 - FRONT OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
3. Remove the front output shaft (1) drive sprocket (2) retaining ring (3). (Scheme 81) 1 - REAR OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
4. Remove the rear output shaft (1) drive sprocket (2) retaining ring (3). (Scheme 82) 1 - FRONT CASE HALF 2 - CHAIN 3 - DRIVE SPROCKETS
5. Pull front sprocket (3), rear sprocket, and chain (2) upward until clear of the front and rear output shaft sprocket splines. (Scheme 83)
6. Remove chain and sprockets as an assembly.

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1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever to sector shaft. Then remove shift lever (3) and spacer from the shaft. (Scheme 84)
3. Remove the sector support (2) with Socket (special tool #9033, Socket, Sector Support). 1 - FRONT CASE 2 - POSITION SENSOR
4. Remove the transfer case position sensor or switch (2) from the front case half (1). (Scheme 85) 1 - FRONT CASE HALF 2 - DETENT PLUG
5. Loosen detent plug (2). (Scheme 86) 1 - FRONT CASE HALF 2 - DETENT PLUG 3 - SPRING 4 - PLUNGER
6. Remove detent plug (2), spring (3), and plunger (4). (Scheme 87) Note that the plug has an O-ring seal. Remove and discard this seal. 1 - FRONT CASE HALF 2 - SNAP-RING
7. Using a screw mounted in a slide hammer, remove the front output shaft seal.
8. Remove the front output shaft snap-ring (2). (Scheme 88) 1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
9. Remove front output shaft (2) from bearing in the front case (1). (Scheme 89) 1 - FRONT CASE HALF 2 - MAINSHAFT ASSEMBLY
10. Pull mainshaft assembly (2) out of input gear, mode sleeve, and case. (Scheme 90) 1 - SHIFT RAIL 2 - MODE FORK 3 - MODE SLEEVE
11. Remove mode fork (2), mode sleeve (3), and shift rail (1) as assembly. (Scheme 91) 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). 1 - RANGE HUB 2 - RANGE FORK
12. Remove range fork (2) and hub (1) as an assembly. (Scheme 92) Note fork position for installation reference. 1 - SHIFT SECTOR
13. Remove shift sector (1). (Scheme 93)

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1. Remove the clutch gear (2) from the output shaft (1). (Scheme 94) 1 - MAINSHAFT 2 - MODE HUB 3 - RETAINING RING
2. Remove the mode hub retaining ring (3) from the mainshaft (1). (Scheme 95) 1 - MAINSHAFT 2 - MODE HUB
3. Remove the mode hub (2) from the mainshaft (1). (Scheme 96) 1 - MAINSHAFT 2 - DRIVE SPROCKET DRIVE HUB
4. Remove the drive sprocket drive hub (2) from the mainshaft. (Scheme 97)

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1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (2) with heavy duty snap-ring pliers. (Scheme 98) 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). (Scheme 99) Tap gear out of bearing with plastic mallet, if necessary. 1 - INPUT GEAR 2 - RETAINING RING
4. Remove snap-ring (2) that retains input gear in the low range gear (1). (Scheme 100) 1 - INPUT GEAR 2 - RETAINER
5. Remove retainer (2). (Scheme 101) 1 - INPUT GEAR 2 - THRUST PLATE
6. Remove front thrust plate (2) from the input gear (1). (Scheme 102) 1 - INPUT GEAR 2 - LOW RANGE PLANETARY
7. Remove input gear (1) from the low range planetary (2). (Scheme 103) 1 - PLANETARY 2 - THRUST PLATE
8. Remove bottom tabbed thrust washer (2) from low range planetary (1). (Scheme 104)