NV273 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.

Scheme 138

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Scheme 141

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 138)
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 139)
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 140) 1 - REAR CASE HALF 2 - EXTENSION HOUSING
8. Remove rear extension housing (2). (Scheme 141) Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.

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Scheme 148

1. Disengage the oil pump pick-up tube (2) from the oil pump (1). (Scheme 142) 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). (Scheme 143) 1 - FRONT CASE HALF 2 - REAR CASE HALF 3 - BOLTS
3. Remove rear case (2) -to-front case (1) bolts (3). (Scheme 144) 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 145) 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 146) 1 - FRONT CASE HALF 2 - REAR CASE HALF
6. Loosen rear case (2) from front case (1) with pry tool to break sealer bead. (Scheme 147) Insert tool at each end of case. 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 148)

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Scheme 152

1. Remove the oil pick-up tube (3) and screen from the front case half (1). (Scheme 149) 1 - FRONT OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
2. Remove the front output shaft (1) drive sprocket (2) retaining ring (3). (Scheme 150) 1 - REAR OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
3. Remove the rear output shaft (1) drive sprocket (2) retaining ring (3). (Scheme 151) 1 - FRONT CASE HALF 2 - CHAIN 3 - DRIVE SPROCKETS
4. Pull front sprocket (3), rear sprocket, and chain (2) upward until clear of the front and rear output shaft sprocket splines. (Scheme 152)
5. Remove chain and sprockets as an assembly.

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Scheme 162

1. Remove the bolts (3) that hold the shift motor assembly (2) to the transfer case (1). (Scheme 153) 1 - TRANSFER CASE 2 - SHIFT MOTOR ASSEMBLY
2. Remove the shift motor assembly (2) from the transfer case (1). (Scheme 154) 1 - FRONT CASE HALF 2 - DETENT PLUG
3. Remove the sector support with Socket (special tool #9033, Socket, Sector Support).
4. Loosen detent plug (2). (Scheme 155) 1 - FRONT CASE HALF 2 - DETENT PLUG 3 - SPRING 4 - PLUNGER
5. Remove detent plug (2), spring (3), and plunger (4). (Scheme 156) Note that the plug has an O-ring seal. Remove and discard this seal. 1 - FRONT CASE HALF 2 - SNAP-RING
6. Using a screw mounted in a slide hammer, remove the front output shaft seal.
7. Remove the front output shaft snap-ring (2). (Scheme 157) 1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
8. Remove front output shaft (2) from bearing in front case (1). (Scheme 158) 1 - FRONT CASE HALF 2 - MAINSHAFT ASSEMBLY
9. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1). (Scheme 159) 1 - MODE SLEEVE 2 - MODE FORK AND RAIL
10. Remove mode fork, mode sleeve (1), and shift rail (2) as assembly. 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
11. Remove range fork (2) and hub (1) as an assembly. (Scheme 161) Note fork position for installation reference. 1 - SHIFT SECTOR
12. Remove the shift sector (1). (Scheme 162)

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Scheme 166

1. Remove the clutch gear (2) from the output shaft (1). (Scheme 163) 1 - MAINSHAFT 2 - MODE HUB 3 - RETAINING RING
2. Remove the mode hub (2) retaining ring (3) from the mainshaft (1). (Scheme 164) 1 - MAINSHAFT 2 - MODE HUB
3. Remove the mode hub (2) from the mainshaft (1). (Scheme 165) 1 - MAINSHAFT 2 - DRIVE SPROCKET DRIVE HUB
4. Remove the drive sprocket drive hub (2) from the mainshaft (1). (Scheme 166)

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Scheme 173

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. (Scheme 167) 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 168) 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 (1) in the low range gear. (Scheme 169) 1 - INPUT GEAR 2 - RETAINER
5. Remove retainer (2). (Scheme 170) 1 - INPUT GEAR 2 - THRUST PLATE
6. Remove front thrust plate (2). (Scheme 171) 1 - INPUT GEAR 2 - LOW RANGE PLANETARY
7. Remove input gear (1). (Scheme 172) 1 - PLANETARY 2 - THRUST PLATE
8. Remove bottom tabbed thrust washer (2) from low range planetary (1). (Scheme 173)