Assembly

NV244 - Transfer Case

ASSEMBLY
Lubricate transfer case components with automatic transmission fluid or petroleum jelly (where indicated) during assembly.

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.







BEARINGS AND SEALS
1. Remove snap-ring that retains front output shaft front bearing in case (Fig. 38). Then remove bearing. Use hammer handle, or hammer and brass punch to tap bearing out of case.






2. Install new front output shaft front bearing with Tool Handle C-4171 and Installer 8033-A with the tapered cone upward (Fig. 39).
3. Install front bearing snap-ring (Fig. 38).






4. Install new front output shaft oil seal with Installer 6952-A (Fig. 40).






5. Remove input shaft bearing with Tool Handle C-4171 and Remover C-4210 (Fig. 41).
6. Install snap-ring on new input shaft bearing.






7. Install new input shaft bearing with Tool Handle C-4171 and Remover C-4210. Install bearing far enough to seat snap-ring against case (Fig. 42).






8. Remove the input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig. 43).






9. Install new pilot bearing with Installer 8128 and Handle C-4171 (Fig. 44).






10. Install new seal in front bearing retainer with Installer 7884 (Fig 45).






11. Remove front output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 46).






12. Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 47). Lubricate bearing after installation.






13. Install new seal in oil pump feed housing with Special Tool 7888 (Fig. 48).






14. Install new pickup tube O-ring in oil pump (Fig. 49).
15. Remove rear retainer bearing with Remover 5065 and Handle C-4171.






16. Install rear bearing in retainer with Handle C-4171 and Installer 5064 (Fig. 50).







DIFFERENTIAL
1. Lubricate differential components with automatic transmission fluid.
2. Install sprocket gear in differential bottom case (Fig. 51).






3. Install differential planet gears and new thrust washers (Fig. 52). Be sure thrust washers are installed at top and bottom of each planet gear.
4. Install differential mainshaft gear (Fig. 52).






5. Align and position differential top case on bottom case (Fig. 53). Align using scribe marks made at disassembly.
6. While holding differential case halves together, invert the differential and start the differential case bolts.
7. Tighten differential case bolts to specified torque.







INPUT GEAR/LOW RANGE
1. Assemble low range gear, input gear thrust washers, input gear and input gear retainer (Fig. 54).






2. Install low range gear snap-ring (Fig. 55).
3. Lubricate input gear and low range gears with automatic transmission fluid.
4. Start input gear shaft into front case bearing.
5. Press input gear shaft into front bearing.






6. Install new input gear snap-ring (Fig. 56).
7. Apply 3 mm (1/8 inch) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to seal surface of front bearing retainer.






8. Install front bearing retainer (Fig. 57). Tighten retainer bolts to ................16 - 25 Nm (12 - 18 ft. lbs.) torque.







SHIFT FORKS AND MAINSHAFT
1. Install new sector shaft O-ring (Fig. 58).
2. Install shift sector.
3. Install new pads on low range fork, if necessary.
4. Assemble low range fork and hub.






5. Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot (Fig. 59).
6. Install bearing on mainshaft.






7. Install differential (Fig. 60).






8. Install differential snap-ring (Fig. 61).






9. Install intermediate clutch shaft (Fig. 62).






10. Install clutch shaft thrust ring (Fig. 63).






11. Install clutch shaft snap-ring (Fig. 64).






12. Inspect mode fork assembly (Fig. 65). Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket (Fig. 65). Replace worn or damaged components.






13. Install mode sleeve in mode fork (Fig. 66). Then, install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.






14. Install mode fork and mainshaft assembly in case (Fig. 67). Rotate mainshaft slightly to engage shaft with low range gears.
15. Rotate mode fork pin into shift sector slot.






16. Install shift rail with the taper to the rear of the transfer case (Fig. 68). Be sure rail is seated in both shift forks.






17. Install detent plunger, detent spring, and detent plug in case (Fig. 69).







FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install front output shaft (Fig. 70).
2. Install drive chain (Fig. 70). Engage chain with front output shaft sprocket teeth.
3. Install drive sprocket (Fig. 70). Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft splines.






4. Install drive sprocket snap-ring (Fig. 71).






OIL PUMP AND REAR CASE
1. Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube. Then install assembled pump, tube and screen in rear case (Fig. 72). Be sure screen is seated in case slot as shown.
2. Clean the transfer case magnet.






3. Install magnet in front case pocket (Fig. 73).
4. Apply 3 mm (1/8 inch) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to seal surface of front case.
5. Align and install rear case on front case. Be sure case locating dowels are in place and that mainshaft splines are engaged in oil pump inner gear.
6. Install and tighten front case to rear case bolts to ...............27 - 34 Nm (20 - 25 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.



REAR RETAINER
1. Apply bead of Mopar Sealer, or LoctiteTM Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch.
2. Install rear retainer on rear case. Tighten retainer bolts to ..........27 - 34 Nm (20 - 25 ft. lbs.) torque.






3. Install new output shaft bearing snap-ring (Fig. 74). Lift mainshaft slightly to seat snap-ring in shaft groove, if necessary.
4. Apply 3 mm (1/8 inch) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of extension housing. Allow sealer to set-up slightly before proceeding.
5. Install extension housing on rear retainer.
6. Install extension housing bolts and tighten to .............27 - 34 Nm (20 - 25 ft. lbs.).


COMPANION FLANGE AND SHIFT MOTOR AND MODE SENSOR ASSEMBLY
1. Position the shift motor and mode sensor assembly onto the transfer case.






2. Install the bolts (Fig. 75) to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to .................16 - 24 Nm (12 - 18 ft. lbs.) torque.

CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite(tm) 242 to replenish the lock patch material originally found on the bolts

NV244 - Transfer Case:

3. Install new seal washer onto the front output shaft (Fig. 76).
4. Lubricate the companion flange hub with transmission fluid and install the flange onto the front output shaft.
5. Install a new companion flange nut onto the front output shaft.
6. Tighten the flange nut to ..........122 - 176 Nm (90 - 130 ft. lbs.) torque. Use Tool 6958, or similar tool to hold flange while tightening nut.