DODGE TRUCK 1993 Service Repair Manual

21
- 340
OVERDRIVE
UNIT OVERHAUL—42RH/46RH

(16) Install governor support snap ring (Fig. 64).

SNAP
/ ©
^S^^S^
/^SCREWDRIVER RING
7

8921-264

Fig.
64 Installing
Governor
Support
Snap Ring

(17) Install output shaft front bearing locating ring
in case (Fig. 65).
OUTPUT SHAFT
FRONT BEARING LOCATING RING

J9121-339

Fig.
65 Front Bearing Locating
Ring
Installation
(18) Support geartrain on Tool 6227-1 (Fig. 66). Be
sure tool is securely seated in clutch hub. (19) Install overdrive unit case over geartrain (Fig.

66).

(20) Expand front bearing locating ring with snap
ring pliers. Then slide case downward until locating ring locks in bearing groove and release snap ring.
(21) Install locating ring access plate and gasket in
overdrive unit case (Fig. 9).
(22) Install overdrive clutch components as follows: (a) Install reaction ring first. Reaction ring is
flat with notched ends (Fig. 67). (b) Install wave spring on top of reaction ring.
Reaction ring and wave ring both fit in same
ring groove. Use screwdriver to seat each ring se­ curely in groove. (c) Install reaction plate (Fig. 68). (d) Install first clutch disc followed by first
clutch plate.
SPECIAL

TOOL
6227-2
CASE

GEARTRAIN
SPECIAL
TOOL
6227-1

J9221-6

Fig.
66 Installing Overdrive
Case
On
Geartrain
(e) Install remaining clutch discs and plates in
same order.
(f) Verify clutch pack before proceeding:
• gas engine version of 42RH/46RH, requires 4
clutch discs, 3 steel plates, 1 reaction plate and 1
pressure plate.
• diesel engine version of 46RH, requires 5 clutch

discs,
4 steel plates, 1 reaction plate and 1 pressure
plate.
(g) Install clutch pack pressure plate (Fig. 68).
(h) Install clutch pack wire-type retaining ring
(Fig. 67).
WAVE

SPRING

REACTION RING RETAINING RING
(WIRE-TYPE)
J9121-470

Fig.
67 Overdrive
Clutch
Ring
Identification
(23) Place overdrive unit in vertical position.
Mount unit in vise or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub.

•

NP205
TRANSFER
CASE
21 - 341

REACTION
PLATE

CLUTCH
DISCS
(4)
J9321-227

Fig.
68 Overdrive
Clutch
Pack
(Gas
Engine
Version

Shown)

(24) Determine correct thickness intermediate
shaft spacer as follows: (a) Insert Special Tool 6312 through sun gear, plan­
etary gear and into pilot bushing in output shaft. Be
sure tool bottoms against planetary shoulder.
(b) Position Gauge Tool 6311 across face of over­
drive case (Fig. 69). Then position Dial Caliper C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Alignment Tool 6312. Lock scale in place. Remove
dial caliper tool and note distance measured (Fig. 69). (d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig. 70). (e) Remove Alignment Tool 6312.
SPECIAL

TOOL
6311

SPECIAL

TOOL
6312

J9221-47
Fig.
69 Shaft End Play Measurement
(25) Determine correct thickness overdrive piston
thrust plate as follows: (a) Position Gauge Tool 6311 across face of over­
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 71).
(b) Measure distance to clutch hub thrust bear­
ing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.
End
Play

Measurement
(Inches)
Spacer
Thickness
(Inches)

.7336
-
.7505
.158
- .159

.7506
-
.7675
.175
- .176

.7676
-
.7855
.193
- .194

.7856-
.8011
.211
- .212

J9121-341 Fig. 70
Intermediate
Shaft
End
Play
Spacer
Selection

(c) Select and install required thrust plate from in­
formation provided in thrust plate chart (Fig. 72).
(26) Leave Alignment Tool 6227-2 in place. Tool
will keep planetary and clutch hub splines in align­
ment until overdrive unit is ready for installation on
transmission.
(27) Set overdrive unit aside for final assembly of
transmission.

Fig.
71 Overdrive
Piston
Thrust
Plate
Measurement
End
Ploy

Measurement
(Inches)
Spacer
Thickness
(Inches)

1.7500
- 1.7649
.108
- .110

1.7650-
1.7799
.123
- .125

1.7800
- 1.7949
.138
- .140

1.7950
- 1.8099
.153
- .155

1.8100
- 1.8249
.168
- .170

1.8250
- 1.8399
.183
- .185

1.8400
- 1.8549
.198
- .200

1.8550
- 1.8699
.213
- .215

1.8700
- 1.8849
.228
- .230

1.8850
- 1.8999
.243
- .245

J9121-342

Fig.
72 Overdrive
Piston
Thrust
Plate
Selection

21
- 342
NP205 TRANSFER CASE

•
NP205
TRANSFER CASE

INDEX
page
General
Information
342
Recommended Lubricants
342

Service Diagnosis
342

Shift
Linkage
Adjustment
344

Speedometer Service
345

GENERAL
INFORMATION

The NP205 transfer case
is a
heavy duty, part-time
unit with constant mesh, helical gears.
The
gears
are

mounted
in a
one-piece, cast iron gear case. The NP205 provides four operating ranges which

are:
4-wheel drive high, neutral, 2-wheel drive high
and 4-wheel drive
low (Fig. 1).
The transfer case gears rotate
on
shafts supported
by ball
and
roller bearings. Sliding clutch sleeves and shift forks
are
used
to
engage
or
disengage
the

drive gears. The NP205 geartrain provides high
and low
ranges
in 4-wheel drive mode.
The
high range
has a 1:1 ra­

tio
for
normal operation
and a low
range with
a re­
duction ratio
of 1.96:1 for
extra pulling power
in off

road situations. In two-wheel drive range,
the
transfer case front
output shaft drive gear
is
disengaged. Torque
is not

transmitted
to the
front propeller shaft.
Fig.
1
NP205 Transfer
case

RECOMMENDED
LUBRICANTS
Recommended lubricants
for the
NP205 transfer
case include multi-purpose gear lubricants
and
single
weight engine oils. Engine
oil
should
be API
classification SF/CC
or

SF/CD.
Use SAE 30 at
ambient temperatures below
0°
C
(
+
32°
F) and SAE 50 at
ambient temperatures
above this point.
page
Transfer
Case
Assembly
348

Transfer
Case
Disassembly
..........
345

Transfer
Case
Identification
342

Transfer
Case
Installation
345

Transfer
Case
Removal
345

SAE multi-purpose gear lubricants with
an API

grade rating
of GL 5 are
recommended
for
severe
duty operation.
SAE
grades
80,
75W-90,
90,
80W-90, 140
and
80W-140
are all
acceptable.
Use
SAE 80 or
75W-90 when ambient tempera­
tures
are
below
-23° C (-10° F). Use SAE 90, or
80W-90 when ambient temperature
is
above
the

stated range.
SAE
140, or
80W-140
can be
used when severe ser­
vice
is
anticipated,
or
when ambient temperatures are expected
to
exceed +32°
C (90° F).

Transfer Case Shift Linkage Lubrication
The transfer case shift linkage pivot
and
contact
surfaces should
be
lubricated with engine
oil at
rec­
ommended intervals. Lubrication frequency
for the

linkage
is
described
in
Lubrication
And
Maintenance Group
O.

TRANSFER CASE
IDENTIFICATION
The NP205 identification
tag is
attached
to the

PTO cover
on the
driver side
of the
transfer case.
The
tag
contains transfer case manufacturing
and as­
sembly part numbers. Refer
to
this information when
ordering service replacement parts.

SERVICE
DIAGNOSIS
The most frequent causes
of
transfer case malfunc­
tions
are:
• improper operation
• insufficient lubricant
• non-recommended lubricant
• misadjusted shift linkage
• improper assembly after repair. The general problems
and
causes
of
transfer case
malfunctions
are
outlined below.

LOW LUBRICANT LEVEL
A
low
lubricant level
is
usually
the
result
of
loose
components, leakage,
or
improper checking and/or
filling techniques. Lubricant leaks
can
occur
at the
shaft seals, case
vent,
or
gasket joints. Most leaks will
be
evident
by

the presence
of
lubricant around
the
leakage point. However,
be
sure
the
leakage
is
actually from
a

transfer case component.

•

NP205 TRANSFER
CASE
21 - 343 Leakage from other sources (engine, transmission,
etc.) can be blown back onto the transfer case by air
flow under the vehicle. A blocked transfer case vent
can also cause leakage at the shaft seals due to in­
ternal pressure build up.
Overfilling the transfer case can force fluid out the
vent and be mistaken for a leak. Correct fluid level checking methods should prevent overfill problems.

Checking
Fluid Level The correct method of checking transfer case fluid
level requires that the vehicle be level.
If fluid level is checked with the vehicle parked on
the shop floor, be sure the floor area used is level. If a hoist is used, a drive-on, or swivel arm type is pre­
ferred.
Allow the transfer case fluid to settle for a minute
or so before checking. Correct fluid level is to the
bottom edge of the fill plug hole.

HARD SHIFTING
Hard shifting is generally caused by:
• misadjusted or binding linkage
• loose linkage or driveline components
• torque loads caused by 4WD operation on hard
paved surfaces • improper shifting techniques
• lack of lubricant which caused internal wear and
damage.
Loose linkage or driveline components are a result
of improperly tightened, stripped, or missing fasten­

ers.
Remember that loose crossmember and mounting
parts can also generate a hard shift condition.
Torque loads in the transfer case can cause hard
shifting or even prevent shifting. Such loads are gen­
erally a product of extensive operation on hard,
paved surfaces in 4WD range, unequal size tires, or
by mismatched front/rear axle gear ratios.
Linkage adjustment should be performed as de­
scribed in the service section. Improper shift and op­
erating techniques can be corrected by instructing
the driver. Internal component damage will require
overhaul to correct.
Failure to lubricate the shift linkage at recom­
mended intervals will cause the linkage to bind. If
bind is severe enough to cause hard shifting, the linkage will have to be removed in order to correct
the condition. The linkage can be soaked in auto­
matic transmission fluid if necessary. The fluid will
break up accumulated rust and corrosion.

NOISE
Some transfer case operating noise is normal. The
rotating gear train can produce sounds that may be­
come audible at higher speeds and loads. However,
unusual noise is an indicator that internal compo­ nents may be worn or damaged. Low lubricant levels are a frequent cause of noisy
operation. Insufficient lubricant will lead to over­
heating, subsequent damage to bearing and gear sur­
faces and hard shifting.
Transfer case bearing noise is higher in pitch than
gear noise. If the unit is noisy in 4WD range only,
the front shaft bearings are probably at fault. If the unit is noisy in all ranges, an overhaul will be nec­
essary to locate the faulty bearing.
Gear noise is lower in pitch and usually most no­
ticeable when engaged and under load. Gear noise in
4WD drive range only is an indicator that the front shaft gears are damaged. Noise in all ranges could be
the idler or drive gears. An overhaul will be neces­ sary to determine which is at fault.
Frequently, suspected transfer case noise may actu­
ally originate from another driveline component. The
proximity of other driveline components can some­
times make it difficult to pinpoint the noise source.

TRANSFER CASE OPERATIONAL CHECK
The transfer case should not be removed until di­
agnosis indicates the unit has actually malfunc­
tioned. If a transfer case problem is suspected, check and verify operation before attempting repair. A
transfer case operational check may reveal that a
problem is actually related to another driveline com­ ponent.
(1) Raise vehicle on a hoist that will allow all four
wheels to rotate. (2) Check lubricant level. If lubricant level is low,
check for leaks at the bearing and seal retainers,

yokes,
drain/fill plugs, PTO cover and vent. (3) If vehicle is equipped with locking hubs, en­
gage hubs. (4) Start engine, shift transmission into gear and
operate transfer case in all ranges. Observe propeller shaft action, shift efforts and operational sound lev­
els as follows: (a) Only the rear propeller shaft should rotate in
two-wheel drive. Both propeller shafts should both
rotate in four-wheel drive high and low ranges. (b) If the front propeller shaft did not rotate in
either four-wheel drive range, the transfer case shift components may be worn or damaged. Or, if
the front shaft did rotate but the front wheels did
not, check the front axle shift mechanism and the locking hubs (if equipped). (c) If both propeller shafts rotate in four-wheel
drive but the wheels on one axle did not rotate, the
problem is in the axle. (d) If neither propeller shaft rotates in any
range, the problem is in the transmission or trans­ fer case. To determine which component is at fault,
proceed to next step. (5) Determine if fault is with transfer case or
transmission as follows:

21 - 344
NP205
TRANSFER
CASE

• (a) Raise vehicle and disconnect both propeller
shafts at the transfer case.
(b) Position supports under the transmission.
(c) Remove the bolts/nuts attaching the transfer
case adapter to the crossmember and transmission. (d) Support the transfer case with a transmission
jack and slide the transfer case and adapter clear of the transmission output shaft.
(e) Have helper start engine and shift transmis­
sion into gear. If transmission output shaft rotates,
problem is with transfer case. If transmission shaft
does not rotate, problem is with transmission or re­ lated component.

SHIFT
LINKAGE
ADJUSTMENT
(1) Shift transfer case into neutral.

(2)
Remove screws attaching shift lever boot and
seal to floor pan (Fig. 2). (3) Slide shift lever boot and seal upward for vi­
sual access to shift gate. Verify that lever is in Neu­
tral position. (4) Loosen bolts" attaching shift lever bracket to
adapter (Fig. 3).
Fig.
2 Shift
Lever
Boot
And
Seal

Fig.
3 NP205 Shift
Linkage

•

NP20I
TRANSFER CASE
21 - 34i (5) Verify that transfer case range lever is in Neu­

tral.
(6) Move shift lever bracket forward and retighten
bracket bolts (Fig. 3). Shift rod should not bind in shift lever and range lever. Rod should be slip-fit
both levers. (7) Shift transfer case into 4H range. Shift rod
should now be tension-fit in each lever. Shift lever
should be in 4H detent in gate and range lever should be fully into 4H position.
(8) Shift transfer case into 2H and 4L ranges to
verify correct adjustment.

SPEEDOMETER SERVICE
The speedometer driven gear, adapter and vehicle
speed sensor can be serviced with the transfer case in
the vehicle.
SPEEDOMETER COMPONENT REMOVAL/
INSTALLATION (FIG. 4) (1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Disconnect wires at vehicle speed sensor.
(4) Loosen and disconnect coupling nut that at­
taches speed sensor to adapter. Then loosen and dis­ connect coupling nut attaching adapter to driven
gear.
(5) Remove vehicle speed sensor and speedometer
adapter. (6) Loosen and remove speedometer driven gear.
(7) Lubricate driven gear with engine or gear oil
and install gear in transfer case. Tighten gear to 11
N*m (100 in. lbs.) torque. (8) Install adapter and speed sensor. Tighten cou­
pling nuts to 17 N»m (150 in. lbs.) torque. (9) Connect wires to speed sensor.
(10) Lower vehicle.

TRANSFER CASE
REMOVAL
(1) Raise vehicle.
(2) Remove drain plug and drain transfer case lu­
bricant. (3) Disconnect vehicle speed sensor wires.
(4) Mark front/rear propeller shafts and yokes for
installation reference. (5) Disconnect and remove propeller shafts. Or dis­
connect shafts at transfer case yokes. Then move shafts aside for working clearance and secure them
to frame rails with wire. (6) Disconnect transfer case shift lever from range
lever on transfer case. (7) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains. (8) Remove nuts attaching transfer case to trans­
mission adapter. (9) Slide transfer case rearward until it is clear of
transmission output shaft.
DISTANCE

SENSOR
ADAPTER
DRIVEN
GEAR
J9021-151

Fig.
4 Speedometer Components.
(10) Lower jack and move transfer case from under
vehicle.
(11) Remove old gasket material from transmission
adapter.

TRANSFER CASE
INSTALLATION
(1) Apply Mopar perfect seal, silicone sealer, or
Permatex No. 2 sealer to both sides of transfer case-
to-transmission gasket. Then position gasket on
transmission. (2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by ro­
tating transfer case rear output shaft yoke if neces­ sary. Do not install any transfer case attaching
nuts until the transfer case is completely seated against the transmission. (3) Install and tighten transfer case attaching nuts
to 47 N*m (35 ft. lbs.). (4) Install rear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect vehicle speed sensor wires.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 N»m (90 in. lbs.). (9) Fill transfer case with recommended lubricant.
(10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.

TRANSFER CASE DISASSEMBLY
(FIG.
S) REAR RETAINER AND OUTPUT SHAFT
REMOVAL/DISASSEMBL
Y
(1) Loosen rear yoke nut until only 2-3 threads are
holding nut on shaft. (2) Remove bolts attaching rear bearing retainer to

case.

(3) Pull yoke rearward to start rear output shaft
out of clutch. (4) Remove rear yoke nut, washer, seal washer and
yoke.

NP205
TRANSFER CASE
21 - 347
LEGEND FOR NP205 TRANSFER CASE

YOKE NUT
®

WASHER
©
SEAL
WASHER
©
REAR
YOKE
©

OIL SEAL
©

REAR
SEAL RETAINER
©

GASKET
©
SNAP
RING
©

REAR
OUTPUT
SHAFT BEARING
©

SPEEDOMETER
GEAR
®
BEARING RETAINER
-
REAR
©

VENT TUBE CONNECTOR
©

GASKET
©

REAR
OUTPUT
SHAFT SUPPORT
©

BEARING
©

LOW GEAR RETAINING RING
THRUST WASHER
(3/16"
THICK)
©
THRUST WASHER
(1/16"
THICK)
©
LOW GEAR ROLLER BEARINGS
[64)
©

BEARING SPACER
©

LOW GEAR
-
REAR SHAFT
©

THRUST WASHER
(1/16"
THICK)
®

REAR
OUTPUT
SHAFT
©

THRUST WASHER PIN
©

SLIDING CLUTCH

PILOT
BEARING ROLLERS
(15) ©

PILOT
BEARING THRUST
©

WASHER
©
LOCK RING
©

INPUT
GEAR
©

IDLER SHAFT COVER
©
GASKET
IDLER SHAFT
IDLER GEAR BEARINGS
BEARING
RACES

BEARING SPACER
IDLER GEAR
IDLER GEAR BEARING SHIMS
WASHER IDLER SHAFT LOCK NUT
THRUST WASHER
PIN
FRONT
OUTPUT
SHAFT
SLIDING CLUTCH

HIGH
GEAR
THRUST WASHER FRONT
OUTPUT
SHAFT FRONT
BEARING
BEARING SNAP RING
FRONT
OUTPUT
SHAFT REAR
BEARING
BEARING RETAINER
-
FRONT
GASKET
RETAINING RING
THRUST WASHER
(3/16"
THICK)
LOW GEAR
-
FRONT SHAFT
LOW GEAR ROLLER BEARINGS
(S3.
iRING
SPACER
FLANGE
OIL SEAL FRONT SEAL RETAINER
GASKET DRAIN PLUG ©
©
©
©
©
©
® ©
©
®
®
©
©
©
©
©
©^
© ©
®
©
©
CASE
MAGNET AND CLIP

FILL
PLUG
PTO COVER AND GASKET
GEAR
CASE

SHIFT RAIL DETENT BALLS
AND SPRINGS
4WD INDICATOR
LIGHT
SWITCH AND GASKET
SHIFT FORK AND RAIL
-
REAR
WHEEL
INTERLOCK PINS
(2)

FORK-TO-RAIL LOCK PIN
SHIFT RAIL OIL
SEALS

SHIFT RAIL
LINK
RETAINING CLIP
(21

LINK-TO-RAIL
RETAINING
PIN

3
HIFT FORK
AND RAIL
-

FRONT WHEEL INTERLOCK HOLE PLUGS
(4)

FRONT
OUTPUT
SHAFT
BEARING
BEARING SNAP RING

INPUT
SHAFT SNAP RING
ADAPTER OIL SEAL
(2)
GASKET

TRANSFER
CASE
ADAPTER ADAPTER SLEEVE
SLEEVE
RETAINING RING
GASKET

TRANSMISSION
ADAPTER

J9021-149

(5)
Remove rear retainer, rear output shaft and
gears as assembly. (6) Remove rear seal retainer from bearing re­
tainer.
(7) Remove snap ring. (8) Remove rear bearing retainer.

(9)
Remove rear bearing, speedometer gear, shaft
support bearings, thrust washer pin and low gear
from rear output shaft (Fig. 5).
(10) Remove lock ring, thrust washer and pilot
bearing rollers from rear output shaft (Fig. 5).
FRONT OUTPUT SHAFT RETAINER REMOVAL (1) Remove front yoke nut, washer and flange (Fig.

5).

(2) Remove front seal retainer and gasket.
(3) Remove PTO cover and gasket.

(4)
Remove detent plug and 4WD indicator light
switch from case (Fig. 5).

(5)
Remove shift rail detent springs and balls (Fig.

5).
Use pencil magnet to remove these components. (6) Remove bolts attaching front bearing retainer
to case. (7) Tap front output shaft with plastic mallet to
loosen it. Then remove shaft, retainer and gears (Fig.
6).
(8) Remove shaft snap ring (Fig. 7).
(9)
Remove thrust washer, gear, bearings and
spacer.

HAMMER

FRONT

OUTPUT
SHAFT
REAR
BEARING

RETAINER
RH320

Fig. 6
Removing/Installing
Front Output Shaft
SHIFT RAIL, IDLER GEAR, INPUT GEAR AND
FRONT SHAFT REMOVAL (1) Remove adapter and gasket. (2) Remove idler shaft nut and washer.
(3) Remove idler shaft cover plate and gasket.

21
- 348 NP20S TRANSFER CASE
Fig. 7 Removing/installing Front Shaft Snap Ring (4) Remove cup plugs at top of case for access to shift
fork lock pins. Use small punch to remove plugs.

(5)
Place shift rails in Neutral position.
(6) Remove lock, pins from shift forks with long
handle easy-out tool (Fig. 8).
Fig. 8 Removing/Installing Shift Fork Lock Pins
(7) Remove pins attaching shift rail link and re­
move link.
(8) Remove shift forks and sliding clutches.
(9) Remove snap ring, thrust washer and bearing
from front shaft.
(10) Remove front shaft and high gear.
(11) Remove input gear, bearing, seals and washer.
(12) Loosen and remove idler shaft with plastic
mallet (Fig. 9).
(13) Tilt case, roll idler gear toward front shaft open­
ing in case and remove gear through this opening.
(14) Remove and retain idler shaft shims. Tie
shims together to avoid losing them.
(15) Remove bearing cups and bearings from idler
gear.
4

Fig. 9 Idler Shaft
Removal
(16) Remove interlock pins from inside case. Re­
move pins through PTO cover opening.
(17) If front output shaft rear bearing must be re­
placed, replace the bearing and retainer as an assem­
bly only.
TRANSFER CASE ASSEMBLY Lubricate the transfer case gears and shafts with
gear oil during assembly. Use petroleum jelly to pre-
lubricate and hold bearings in place during installa­
tion. Use new gaskets and seals throughout. Do not re­
use these components. Replace snap rings if distorted
or damaged and use new yoke locknuts to secure the
yoke and flange. (1) Install bearing cups in idler gear with shop
press (Fig. 10).
(2) Assemble idler gear, gear bearing cones, bear­
ing spacer and shims on Shaft Tool DD1272 (Fig. 10).
(3) Check gear end play (Fig. 10). End play should
be 0.000 to 0.05 mm (0.000 to 0.002 in.). Add or re­
move shims as needed to adjust end play.
(4) Press shift rail seals into case. Seals are wiper-
type and should be installed with seal lip facing out­
ward.
(5) Install assembled idler gear assembly and shaft
tool in case. Insert assembly through front shaft

bore,
large end first. Tilt case at 45° angle to ease
bearing installation at boss (Fig. 11).
(6) Install idler shaft. Insert shaft from large bore
side and tap shaft into gear and bearings with dead-
blow hammer. Remove shaft alignment tool as idler shaft pushes it out of gear and case. (7) Install idler shaft washer and new locknut.
Check end play and free rotation. Tighten locknut to
203 N-m (150 ft. lbs.). (8) Install front bearing and snap ring on input
gear. (9) Assemble front output shaft. Install gears, slid­
ing clutch, bearings, thrust washer pin, thrust wash­

ers,
snap ring and retainer on front output shaft.

1
•
NP241
TRANSFER CASE
21 - 349

Fig.
11 Installing Idler Gear (10) Install interlock pins through large case bore
or PTO opening,
(11) Install input gear in case. Then install sliding
clutch on input gear and position shift fork in clutch.
(12) Install rear wheel shift rail into case (from

back),
with slotted end first and detent notches fac­ ing up (Fig. 8). Then push rail through shift fork and
into opposite end of case.
(13) Install front output shaft in case.
(14) Install front wheel shift fork in sliding clutch
on front shaft. Then install front wheel shift rail into
case and through shift fork.
(15) Secure shift forks to shift rails with new lock

pins.
Install pins through small bores at top of case.
(16) Install front output shaft bearing retainers.
Be sure oil drain slot in bearing retainer is aligned with drain hole in case before tightening

bolts.
Use new gaskets and apply sealer to bolt
threads before installation. Use extra gasket on re­
tainers if necessary. (17) Install flange on front shaft. Install seal washer
on shaft and install flange locknut finger tight. (18) Install washer, seals gasket and adapter on
input shaft (Fig. 5). (19) Install shift link and link retaining pins, clips.
(20) Assemble rear output shaft. Install gears,
bearings and spacers (Fig. 5).
(21) Install new snap ring. Tap ring to seat it and
check end play. End play should be 0.05 to 0.68 mm (0.002 to 0.027 in.).
(22) Install pilot bearing rollers in rear output
shaft. Use as much petroleum jelly as needed to hold
bearing rollers in place.
(23) Install pilot bearing thrust washer and new
snap ring. (24) Install retainer on rear output shaft install
speedometer gear and spacer, install bearing (Fig. 12).
Fig.
12
Assembling
Rear Retainer And Output Shaft
(25) Install retainer and shaft assembly. Be sure
oil drain slot in retainer is aligned with drain
hole in case. Use one or two retainer gaskets de­
pending on clearance. Tighten retainer bolts to 54
N»m (40 ft. lbs.).
(26) Install seals in front and rear seal retainers.
Position gaskets on case and install retainers over shafts and against case. Tighten bolts to 54 Nnn (40
ft. lbs.). (27) Install yoke and flange. Tighten yoke and
flange nuts to 176 N» (130 ft. lbs.).
(28) Install detent balls, springs, plugs, cup plugs
and 4WD indicator light switch.
(29) Install drain plug.
(30) Fill transfer case to bottom edge of fill plug
hole with recommended lubricant.
(31) Install fill plug.