NV247 Transfer Case

NV247 TRANSFER CASE

DISASSEMBLY

Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.

Rear Retainer And Oil Pump Removal

Fig. 14:

1. Remove rear retainer bolts.

Fig. 15:

2. Remove rear bearing locating ring access plug.

Fig. 16:

3. Loosen rear retainer with pry tool to break sealer bead. Pry only against retainer boss as shown.
4. Remove rear retainer as follows:

Fig. 17:

a. Spread rear bearing locating ring with snap ring pliers.

Fig. 18:

b. Then slide retainer off mainshaft and rear bearing.
5. Remove rear bearing snap-ring.
6. Remove rear bearing. Note position of bearing locating ring groove for assembly reference.

Fig. 19:

7. Disengage oil pickup tube from oil pump and remove oil pump assembly.

Fig. 20:

8. Remove pick-up tube O-ring from oil pump, if necessary. Do not disassemble the oil pump, it is not serviceable.

Progressive Coupling Removal

Fig. 21:

1. Remove oil pump locating snap-ring and progressive coupling snap-ring from mainshaft.
2. Remove progressive coupling from mainshaft.

Companion Flange And Range Lever Removal

1. Remove front companion flange nut as follows:
a. Move range lever to 4L position.
b. Remove nut with socket and impact wrench.
2. Remove companion flange. If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned on flange and not on slinger as slinger will be damaged.
3. Remove seal washer from front output shaft. Discard washer as it should not be reused.
4. Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft.

NOTE: Note position of range lever so it can be reinstalled correctly.

Front Output Shaft And Drive Chain Removal

1. Support transfer case so rear case is facing upward.

Fig. 22:

2. Remove bolts holding front case to rear case. The case alignment bolt require flat washers.

Fig. 23:

3. Loosen rear case with flat blade screwdriver to break sealer bead. Insert screwdriver blade only into notches provided at each end of case.

Fig. 24:

4. Remove rear case.

Fig. 25:

5. Remove oil pickup tube from rear case.

Fig. 26:

6. Remove drive gear snap-ring.
7. Disengage drive gear. Pry gear upward and off mainshaft as shown.
8. Remove front output shaft, drive chain and drive gear as assembly.
9. Remove output shaft drive gear snap ring.
10. Remove output shaft drive gear from output shaft.

Shift Forks And Mainshaft Removal

Fig. 27:

1. Remove detent plug, O-ring, detent spring and detent plunger.
2. Remove shift rail from shift fork and transfer case housing.
3. Rotate range shift fork until it disengages from shift sector.
4. Remove mainshaft and shift fork from input gear pilot bearing.

NOTE: Loose needle bearings are used to support the drive sprocket hub on the mainshaft. Do not lift mainshaft by drive sprocket hub or needle bearings will become dislodged.

5. Wrap rag around mainshaft underneath drive sprocket hub and remove drive sprocket hub from mainshaft. Be sure to retrieve all the drive sprocket hub needle bearings.
6. Remove snap ring holding clutch sleeve onto mainshaft.

Fig. 28:

7. Remove range clutch sleeve, blockout spring, locking clutch, and locking clutch spring from mainshaft.

Fig. 29:

8. Remove shift sector. Rotate and tilt sector as needed to remove it.

Fig. 30:

9. Remove shift sector bushing and O-ring.

Input Gear/Low Range Assembly Removal

1. Turn front case on side so front bearing retainer is accessible.

Fig. 31:

2. Remove front bearing retainer bolts.
3. Remove front bearing retainer as follows:

Fig. 32:

a. Loosen retainer with flat blade screwdriver
to break sealer bead. To avoid damaging case and retainer, position screwdriver blade only in slots provided in retainer.
b. Then remove retainer from case and gear.

Fig. 33:

4. Remove snap-ring that retains input gear shaft in front bearing.

Fig. 34:

5. Remove input and low range gear assembly.
6. Remove oil seals from following components: front bearing retainer. rear retainer case halves.

Input And Low Range Gear Disassembly

Fig. 35:

1. Remove snap-ring that retains input gear in low range gear.

Fig. 36:

2. Remove retainer.

Fig. 37:

3. Remove front tabbed thrust washer.

Fig. 38:

4. Remove input gear.

Fig. 39:

5. Remove rear tabbed thrust washer from low range gear.

ASSEMBLY

Lubricate transfer case components with Mopar Transfer Case Fluid (05016796AC) 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.

Bearing And Seal Installation

Fig. 40:

1. Remove front output shaft seal from front case with pry tool.

Fig. 41:

2. Remove snap-ring that retains front output shaft bearing in front case.

Fig. 42:

3. Using tool 6953, remove bearing from front case.
4. Using tool 6953, install new bearing.
5. Install snap-ring to hold bearing into case.
6. Install new front output seal in front case with Installer Tool 6952-A as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.

Fig. 43:

b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool bottoms against case.

Fig. 44:

7. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148.

Fig. 45:

Fig. 46:

8. Install new bearing with Tool Handle C-4171 and Installer 5066. The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer.

Fig. 47:

9. Using Remover C-4210 and Handle C-4171, drive input shaft bearing from inside the annulus gear opening in the case..
10. Install locating ring on new bearing.
11. Position case so forward end is facing upward.

Fig. 48:

12. Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated against case surface.

Fig. 49:

13. Remove 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. 50:

14. Install new pilot bearing with Installer 8128 and Handle C-4171.
15. Remove front bearing retainer seal with suitable pry tool.

Fig. 51:

16. Install new front bearing retainer with Installer 7884.

Input And Low Range Gear Assembly

Fig. 52:

1. Lubricate gears and thrust washers with recommended transmission fluid.
2. Install first thrust washer in low range gear. Be sure washer tabs are properly aligned in gear notches.
3. Install input gear in low range gear. Be sure input gear is fully seated.
4. Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
5. Install retainer on input gear and install snap ring.

Input Gear/Low Range Installation

Fig. 53:

1. Align and install low range/input gear assembly in front case. Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.

Fig. 54:

2. Install snap-ring to hold input/low range gear into front bearing.
3. Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
4. Apply a 3 mm (1/8 inch) bead of MOPAR gasket maker or silicone adhesive to sealing surface of retainer.
5. Align cavity in seal retainer with fluid return hole in front of case.

CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying MOPAR gasket maker or silicone adhesive sealer. Seal failure and fluid leak can result.

Fig. 55:

6. Install bolts to hold retainer to transfer case. Tighten to 21 Nm (16 ft. lbs.) of torque.

Shift Forks And Mainshaft Installation

Fig. 56:

1. Install new sector shaft O-ring and bushing.

Fig. 57:

2. Install shift sector.

Fig. 58:

3. Install locking clutch spring, locking clutch, blockout spring, and range clutch sleeve, to mainshaft as shown. Install snap ring.
4. Install drive sprocket hub to mainshaft. and manually load the needle bearings.
5. Install new pads on range fork, if necessary.
6. Install range shift fork to range clutch sleeve. Install mainshaft/range shift fork assembly into transfer case and input planetary assembly. Rotate fork until it engages with slot in shift sector.
7. Install shift rail to shift range fork and transfer case housing.
8. Rotate shift sector to Neutral position.

Fig. 59:

9. Install new O-ring on detent plug.
10. Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
11. Install detent plunger, spring and plug.
12. Verify that plunger is properly engaged in sector.

Front Output Shaft And Drive Chain Installation
1. Lubricate front output shaft-sprocket assembly, drive chain and drive sprocket with transmission fluid.

Fig. 60:

2. Assemble drive chain, drive sprocket and front output shaft.
3. Start drive sprocket on mainshaft.
4. Guide front shaft into bearing and drive sprocket onto mainshaft drive gear.

Fig. 61:

5. Install drive sprocket snap-ring.
6. Install roller bearings if removed.

Fig. 62:

7. Install progressive coupling.

Fig. 63:

8. Install oil pickup tube in rear case. Be sure tube is seated in case notch as shown.

Fig. 64:

9. Install magnet in front case pocket.
10. Clean sealing flanges of front case and rear case with a wax and grease remover.

Fig. 65:

11. Apply 3 mm (1/8 inch) wide bead of MOPAR gasket maker or silicone adhesive sealer to mounting flange of front case. Work sealer bead around bolt; holes as shown.

Fig. 66:

12. Align and install rear case on front case.

Fig. 67:

13. Verify that oil pickup tube is still seated in case notch and tube end is pointed toward mainshaft.

Fig. 68:

14. Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers.
15. Tighten case bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.

Companion Flange And Range Lever Installation

Fig. 69:

1. Install range lever, washer and locknut on sector shaft. Tighten locknut to 27 - 34 Nm (20 - 25 ft. lbs.) torque.

Fig. 70:

2. Install new seal washer on front output shaft.
3. Lubricate flange hub with transmission fluid and install flange on front shaft.
4. Install new seal washer on front shaft.
5. Install companion flange and new nut on front output shaft.
6. Tighten flange nut to 122 - 176 Nm (90 - 130 ft. lbs.) torque. Use Tool C-3281, or similar tool to hold flange while tightening yoke nut.

Progressive Coupler

Fig. 71:

1. Install coupling on mainshaft.
2. Install coupling retaining snap-ring first. Be sure snap ring is fully seated before proceeding.
3. Install oil pump locating snap-ring on mainshaft.

Rear Retainer And Oil Pump Installation
1. Install new O-ring on flanged end of oil pickup tube.

Fig. 72:

2. Install oil pump.

Fig. 73:

3. Insert oil pickup tube in pump.
4. Install rear bearing on mainshaft. Locating ring groove in bearing goes toward end of mainshaft.

Fig. 74:

5. Install rear bearing retaining snap-ring.
6. Install rear bearing locating ring in rear retainer, if ring was removed during overhaul.
7. Apply 3 mm (1/8 inch) wide bead of MOPAR gasket maker or silicone adhesive sealer to mounting surface of rear retainer. Allow sealer to set-up slightly before proceeding.

Fig. 75:

8. Slide rear retainer onto mainshaft.

Fig. 76:

9. Spread rear bearing locating ring and slide rear retainer into place on rear case.
10. Install and tighten rear retainer bolts to 27 - 34 Nm (20 - 25 ft. lbs.).

Fig. 77:

11. Install rubber access plug.

Final Assembly
1. Install drain plug. Tighten plug to 41 - 54 Nm (30 - 40 ft. lbs.) torque.
2. Level transfer case and fill it with Mopar Transfer Case Fluid (05016796AC). Correct fill level is to bottom edge of fill plug hole.
3. Install and tighten fill plug to 41 - 54 Nm (30 - 40 ft. lbs.) torque.