DODGE RAM 2002 Service Repair Manual

DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved surfaces.
3) Transfer case external shift
linkage binding.3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding,
worn, or damaged.5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
21 - 468 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and vacuum harness at
transfer case switch.
(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) Remove rear crossmember.
(9) Mark front and rear propeller shafts for assem-
bly reference.
(10) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Move transfer case assembly rearward until
free of transmission output shaft.
(14) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
EXTENSION HOUSING
(1) Remove extension housing snap-ring access
cover.
(2) Remove bolts holding extension housing to rear
case half.
(3) Tap extension housing with plastic or rawhide
hammer to loosen sealant.
(4) Disengage extension housing snap-ring from
rear output shaft bearing.
(5) Separate extension housing from transfer case.
COMPANION FLANGE AND SHIFT LEVER
(1) Shift transfer case into NEUTRAL.
(2) Remove companion flange nut (Fig. 3). Discard
nut after removal. It is not reusable.
(3) Remove companion flange from front output
shaft. Use a suitable puller if flange can not be
removed by hand.
(4) Remove companion flange rubber seal from
front output shaft (Fig. 4).(5) Remove nut and washer that retain shift lever
to sector shaft. Then remove shift lever from shaft
(Fig. 5).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove output bearing retaining ring with
heavy duty snap-ring pliers.
(2) Remove output shaft bearing.
(3) Note position of bolts that attach rear case to
front case (Fig. 6). Some bolts/studs at ends of case
Fig. 3 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - 1-1/8º SOCKET
Fig. 4 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 5 Shift Lever Removal
1 - SHIFT LEVER
2 - NUT/WASHER
BR/BETRANSFER CASE - NV241HD 21 - 469
TRANSFER CASE - NV241HD (Continued)

require flat washers. Mark position of these bolts
with paint or scriber.
(4) Remove rear case-to-front case bolts.
(5) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 7).(6) Unseat rear case from alignment dowels (Fig.
8).
(7) Remove rear case and oil pump assembly from
front case.
(8) Remove shift rail cup and spring (Fig. 9).
Fig. 6 Removing Case Attaching Bolts
1 - REAR CASE
2 - STUD
3 - NUT AND WASHER
4 - SOCKET
Fig. 7 Loosening Rear Case (Breaking Sealer Bead)
1 - SLOT
2 - REAR CASE
3-PRYTOOL
Fig. 8 Removing Rear Case From Alignment Dowels
1 - CASE DOWELS (2)
2 - REAR CASE
Fig. 9 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
21 - 470 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(9) Remove front sprocket retaining ring (Fig. 10).
(10) Pull mainshaft, front sprocket, and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
11).
(11) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as an assembly.SHIFT FORK AND MAINSHAFT
(1) Remove vacuum/indicator switch (Fig. 12).
(2) Loosen poppet plunger screw (Fig. 13).
(3) Remove poppet plunger screw and spring (Fig.
14). Note that screw has o-ring seal. Remove and dis-
card seal this seal.
Fig. 10 Removing Front Drive Sprocket Retaining
Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 11 Removing Drive Chain And Front Sprocket
1 - CHAIN
2 - DRIVE SPROCKET
3 - FRONT SPROCKET
Fig. 12 Vacuum/Indicator Switch Removal
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 13 Loosening Poppet Plunger Screw
1 - POPPET PLUNGER SCREW
Fig. 14 Poppet Plunger Screw And Spring Removal
1 - POPPET PLUNGER SCREW
2 - O-RING
3 - PLUNGER SPRING
BR/BETRANSFER CASE - NV241HD 21 - 471
TRANSFER CASE - NV241HD (Continued)

(4) Remove poppet plunger with magnet (Fig. 15).
(5) Remove front output shaft from bearing in case
(Fig. 16).(6) Pull mainshaft assembly out of input gear, slid-
ing clutch and case (Fig. 17).
(7) Remove mode fork, sliding clutch and shift rail
as assembly (Fig. 18). Note which way clutch fits in
fork (long side of clutch goes to front).
Fig. 15 Poppet Plunger Removal
1 - MAGNET
2 - POPPET PLUNGER
Fig. 16 Front Output Shaft Removal
1 - BALL BEARING
2 - FRONT OUTPUT SHAFT
Fig. 17 Mainshaft Assembly Removal
1 - SLIDING CLUTCH
2 - MODE FORK
3 - MAINSHAFT ASSEMBLY
Fig. 18 Mode Fork, Shift Rail And Sliding Clutch
Removal
1 - MODE FORK
2 - SHIFT RAIL
3 - SLIDING CLUTCH
21 - 472 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(8) Remove sliding hub retaining ring (Fig. 19).
(9) Remove range fork and sliding hub as an
assembly (Fig. 20).
(10) Remove shift sector (Fig. 21).
(11) Remove shift sector shaft nylon retainer and
o-ring from shaft bore in front case (Fig. 22).
Fig. 19 Sliding Hub Retaining Ring Removal
1 - RETAINING RING
2 - RANGE FORK
3 - SLIDING HUB
Fig. 20 Range Fork And Sliding Hub Removal
1 - SUPPORT SLEEVE
2 - RANGE FORK
Fig. 21 Shift Sector Removal
1 - SHIFT SECTOR
2 - SECTOR SHAFT
Fig. 22 Removing Sector Shaft O-Ring And Retainer
1 - SHAFT BORE
2 - NYLON RETAINING RING
3 - SECTOR SHAFT O-RING
BR/BETRANSFER CASE - NV241HD 21 - 473
TRANSFER CASE - NV241HD (Continued)

MAINSHAFT
(1) Remove retaining ring that secures synchro-
nizer hub on mainshaft (Fig. 23). Use standard
(instead of parallel jaw) snap-ring pliers to remove
this retaining ring.
(2) Remove synchronizer hub (Fig. 24).(3) Inspect synchronizer hub struts and springs. If
struts appear worn, remove struts and springs from
hub. Note position of springs for installation refer-
ence (Fig. 25).
(4) Remove brass stop ring (Fig. 26). Discard stop
ring if worn, cracked, or any teeth are missing.
Fig. 23 Synchronizer Hub Retaining Ring Removal
1 - SYNCHRO HUB
2 - RETAINING RING
Fig. 24 Synchronizer Hub Removal
1 - SYNCHRO HUB
2 - MAINSHAFT
Fig. 25 Synchronizer Strut And Spring Removal
1 - SYNCHRO STRUTS
2 - SYNCHRO HUB
3 - SYNCHRO SPRINGS
Fig. 26 Synchronizer Stop Ring Removal
1 - DRIVE SPROCKET
2 - STOP RING
21 - 474 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(5) Remove drive sprocket (Fig. 27).
INPUT AND PLANETARY GEAR
(1) Remove input bearing retainer bolts (Fig. 28).(2) Loosen bearing retainer with pry tool. Insert
tool in retainer slot as shown (Fig. 29). Then remove
retainer.
(3) Remove input gear retaining ring with heavy
duty parallel jaw snap-ring pliers (Fig. 30).
Fig. 27 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
Fig. 28 Removing Input Bearing Retainer Bolts
1 - BEARING RETAINER
2 - INPUT GEAR
Fig. 29 Loosening/Removing Input Bearing Retainer
1 - BEARING RETAINER
2 - SLOT
3-PRYTOOL
Fig. 30 Removing Input Gear Retaining Ring
1 - RETAINING RING
2 - INPUT BEARING
3 - INPUT GEAR
BR/BETRANSFER CASE - NV241HD 21 - 475
TRANSFER CASE - NV241HD (Continued)

(4) Tap input gear out of bearing with plastic mal-
let (Fig. 31).
(5) Remove input gear and planetary/PTO gear as
assembly (Fig. 32).
INPUT AND PLANETARY GEAR
The only removable parts in the planetary assem-
bly are the snap-rings, needle bearing, thrust wash-
ers, lock ring, input gear, and support sleeve.The
planetary carrier, PTO gear, planetary pinions,and remaining planetary components are fixed
parts and are serviced as an assembly.
(1) Position planetary assembly so PTO gear is on
bench (Fig. 33).
(2) Remove retaining ring that secures input gear
and lock ring in planetary assembly.
(3) Remove lock ring and front thrust washer from
carrier (Fig. 34). Note that lock ring and thrust
washer are both tabbed.
(4) Remove input gear from planetary carrier (Fig.
35). Lift gear straight up and out of carrier.
(5) Remove support sleeve from carrier (Fig. 36).
(6) Remove rear thrust washer (Fig. 37).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3MŸ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
If any pump component is worn, or damaged, the
pump must be replaced as an assembly.
Fig. 31 Removing Input Gear
1 - BEARING
2 - INPUT GEAR
3 - PLASTIC MALLET
Fig. 32 Input Gear And Planetary Assembly
Removal
1 - INPUT GEAR
2 - PLANETARY AND PTO GEAR ASSEMBLY
Fig. 33 Removing Lock Ring/Input Gear Retaining
Ring
1 - INPUT GEAR
2 - PLANETARY ASSEMBLY
3 - PTO GEAR
4 - RETAINING RING
21 - 476 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

Inspect the spline teeth on the synchronizer hub
(Fig. 38). If evidence of chipping or excessive wear is
apparent, replace the hub. The hooked end of each
synchronizer spring should be inserted in one of the
struts. In addition, the springs should not interfere
with the polished gear cone or inside diameters of
the hub.
Inspect the stop ring for cracks and wear. Replace
the ring if necessary or if doubt exists over condition.
Check a replacement synchronizer ring for proper fit
on the cone with a minimum of wobble. Also check
the synchronizer struts for wear or damage.
Inspect all gear teeth and splines for wear or dam-
age. Also check splines for burrs, or nicks. Removeminor nicks and scratches with an oil stone. Replace
any part with damaged splines.
It is recommended that all retaining rings be
replaced during overhaul. Most of the retaining rings
can be distorted during removal and should not be
reused.
Inspect the two case halves, for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary. How-
ever, stripped threads can be repaired with Heli-
CoilŸ stainless steel thread inserts. The case vent
tube can be resecured with LoctiteŸ 680 if necessary.
Inspect the annulus gear. Be sure the gear teeth
are in good condition. Replace the front case and
annulus as an assembly if the gear is damaged.
Fig. 34 Planetary Lock Ring And Front Thrust
Washer Removal
1 - THRUST WASHER
2 - PLANETARY
3 - LOCK RING
Fig. 35 Removing Input Gear From Planetary Carrier
1 - INPUT GEAR
2 - PLANETARY CARRIER
Fig. 36 Support Sleeve Removal
1 - SUPPORT SLEEVE
2 - PLANETARY CARRIER
Fig. 37 Rear Thrust Washer Removal
1 - REAR THRUST WASHER
2 - PLANETARY CARRIER
BR/BETRANSFER CASE - NV241HD 21 - 477
TRANSFER CASE - NV241HD (Continued)