NV241LD Transfer Case

REMOVAL
1. Shift transfer case into neutral.

Fig. 10:

2. Remove companion flange nut (Fig. 10). Discard nut after removal. It is not reusable.
3. Remove companion flange from output shaft. Use a suitable puller if flange can not be removed by hand.

Fig. 11:

4. Remove companion flange rubber seal from front output shaft (Fig. 11).
5. Remove front output shaft seal with suitable pry tool, or a slide hammer mounted screw.


INSTALLATION

Fig. 12:

1. Install new front output seal in front case with Installer Tool 6888 and Tool Handle C-4171 (Fig. 12) as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.
b. Start seal in bore. Once seal is started, continue tapping seal into bore until installer tool bottoms against case.

Fig. 13:

c. Remove installer and verify that seal is recessed the proper amount. Seal should be 2.03 to 2.5 mm (0.080 to 0.100 inch) below top edge of seal bore in front case (Fig. 13). This is correct final seal position.

CAUTION: Be sure the front output seal is seated below the top edge of the case bore as shown. The seal could loosen, or become cocked if not seated to recommended depth.

Fig. 14:

2. Install companion flange seal on front shaft (Fig. 14).

Fig. 15:

3. Install companion flange on front shaft (Fig. 15). Then install and tighten flange nut to 176 - 271 Nm (130 - 200 ft. lbs.) torque.