NV271 Transfer Case - Service Information: Removal & Installation RAM Pickup 2500

REMOVAL

1. Raise and support vehicle.
2. Remove skid plate, if equipped. Refer to «PLATE, Skid, Front , Removal»(ref-457829-S37099224772012030200000) and «PLATE, Skid, Transfer Case , Removal»(ref-457829-S06628527422012030200000) .
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. Refer to «SHAFT, Drive, Front Heavy Duty , Removal»(ref-457778-S29439826002012030200000) and «SHAFT, Drive, Rear Heavy Duty , Removal»(ref-457778-S33381732642012030200000) .
10. Support transfer case with suitable jack. Secure transfer case to jack with safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission output shaft.
13. Lower jack and move transfer case from under vehicle.

INSTALLATION

1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with transmission output shaft. Align splines by rotating transfer case rear output shaft yoke if necessary. Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41 N.m (20-30 ft. lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. Refer to «SHAFT, Drive, Front Heavy Duty , Installation»(ref-457778-S09275572762012030200000) and «SHAFT, Drive, Rear Heavy Duty , Installation»(ref-457778-S28269825252012030200000) .
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fill plug.
9. Install skid plate, if equipped. Refer to «PLATE, Skid, Front , Installation»(ref-457829-S14162190652012030200000) and «PLATE, Skid, Transfer Case , Installation»(ref-457829-S13100768802012030200000) .
10. Lower vehicle.

1. Shift transfer case into 2H.
2. Raise and support the vehicle.
3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever.
4. Lower vehicle.
5. Remove transfer case shifter knob cap.
6. Remove nut holding shifter knob (2) to shift lever. (Схема №93)
7. Remove shifter knob.
8. Remove the shift boot from the shifter console.
9. Remove the bolts securing the shifter mechanism to the floor pan.
10. Separate shift lever mechanism from the vehicle.

1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the position.
2. Position shift lever in vehicle.
3. Install the bolts to hold the shifter mechanism (4) to the floor pan. (Схема №94)
4. Raise vehicle.
5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward.
6. Install trunnion to shift lever, if necessary.
7. Install shift rod to trunnion, if necessary.
8. Tighten the shift rod lock bolt to 10 N.m (90 in. lbs.).
9. Remove the shifter adjustment locating pin from the adjustment channel and the locating hole.
10. Lower vehicle.
11. Install the transfer case shifter console.
12. Install the shifter boot and the shifter knob onto the shifter lever.
13. Install nut to hold shifter knob to shift lever.
14. Install shifter knob cap.
15. Verify transfer case operation.

1. Remove the front propeller shaft. Refer to «SHAFT, Drive, Front Heavy Duty, Removal»(ref-457778-S29439826002012030200000).
2. Install two bolts 180° apart into the front output shaft companion flange.
3. Place Yoke Holder (special tool #6719A, Holder, Yoke) (1) over the bolts (2) and against the companion flange. (Схема №95)
4. Remove and discard the front companion flange nut.
5. 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.
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 companion flange onto the front output shaft.
3. Install two bolts 180° apart into the front output shaft companion flange.
4. Place Yoke Holder (special tool #6719A, Holder, Yoke) (1) over the bolts (2) and against the companion flange. (Схема №96)
5. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 N.m (130-200 ft. lbs.).
6. Install front propeller shaft. Refer to «SHAFT, Drive, Front Heavy Duty, Installation»(ref-457778-S09275572762012030200000).

1. Raise and support vehicle.
2. Remove rear propeller shaft. Refer to «SHAFT, Drive, Rear Heavy Duty, Removal»(ref-457778-S33381732642012030200000).
3. Use a suitable chisel or pry tool to remove the rear extension housing dust boot (2). (Схема №97)
4. Use a suitable chisel or pry tool to remove the rear extension housing seal.

1. Clean fluid residue from sealing surface and inspect for defects.
2. Install the extension housing dust boot and seal assembly with Seal Installer (special tool #9037, Installer, Dust Boot/Seal) (3) and Universal Handle (special tool #C-4171, Driver Handle, Universal) (2). (Схема №98)
3. Install propeller shaft. Refer to «SHAFT, Drive, Rear Heavy Duty, Installation»(ref-457778-S28269825252012030200000).
4. Verify proper transfer case fluid level.
5. Lower vehicle.

1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the position sensor.
3. Remove the position sensor from the transfer case.

1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 N.m (20 ft. lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.