DODGE RAM 2001 Service Repair Manual

(10) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 70). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(11) Assemble and install range fork and hub (Fig.
71). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install mode fork and shift rail in sliding
clutch (Fig. 72).
Fig. 69 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTHNOTALIGNED WITH STRUT
4 - STRUT
Fig. 70 Shift Sector Installation
1 - SHIFT SECTOR
Fig. 71 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 72 Assembling Mode Fork And Mainshaft
1 - SLIDING CLUTCH
2 - MODE FORK AND SHIFT RAIL
21 - 876 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(14) Install mainshaft/mode fork assembly (Fig.
73). Guide mainshaft through hub and into input
gear and shift rail through range fork and into case
bore.
(15) Install new o-ring on vacuum/indicator switch,
if necessary.Install vacuum/indicator switch (Fig. 74).
Tighten switch to 20-34 N´m (15-25 ft. lbs.) torque.
(16) Install new sector shaft o-ring and o-ring
retainer in sector shaft bore (Fig. 75). Lubricate
o-ring with transmission fluid or petroleum jelly after
installation.(17) Install shift lever on sector shaft (Fig. 76).
(18) Install washer and nut on sector shaft to
secure shift lever. Apply 1-2 drops MopartLock N'
Seal, or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N´m (20-25 ft. lbs.) torque.
Fig. 73 Installing Mainshaft And Mode Fork
Assembly
1 - MAINSHAFT AND MODE FORK ASSEMBLY
2 - SHIFT RAIL
3 - RANGE FORK
Fig. 74 Vacuum/Indicator Switch Installation
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 75 Sector Shaft O-Ring And Retainer
Installation
1 - SECTOR SHAFT BORE
2 - O-RING
3 - O-RING RETAINER
Fig. 76 Shift Lever Installation
1 - SHIFT LEVER
2 - NUT/WASHER
BR/BETRANSFER CASE - NV241LD 21 - 877
TRANSFER CASE - NV241LD (Continued)

(19) Install poppet plunger and spring (Fig. 77).
(20) Install new o-ring on poppet screw and install
screw in front case (Fig. 78). Tighten screw to 16-24
N´m (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install front output shaft in bearing (Fig. 79).
(2) Insert front sprocket in drive chain (Fig. 80).
(3) Install drive chain around mainshaft sprocket
(Fig. 80). Then position front sprocket over front
shaft.
(4) Raise mainshaft about 2.54 cm (one inch) and
seat front sprocket on front output shaft.
(5) If mainshaft and mode sleeve were unseated
during chain installation, align and reseat mainshaft
in input gear and hub.
Fig. 77 Poppet Plunger And Spring Installation
1 - POPPET PLUNGER AND SPRING
Fig. 78 O-Ring Installation On Poppet Plunger
Screw
1 - O-RING
2 - PLUNGER SCREW
Fig. 79 Front Output Shaft Installation
1 - FRONT OUTPUT SHAFT
2 - BEARING
Fig. 80 Drive Chain And Front Sprocket Installation
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
3 - FRONT SPROCKET
4 - FRONT SHAFT
21 - 878 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(6) Install front sprocket retaining ring (Fig. 81).
(7) Install spring and cup on shift rail (Fig. 82).
(8) Insert magnet in front case pocket (Fig. 83).OIL PUMP AND REAR CASE
Lubricate the oil pump components with before
installation. Prime the oil pickup tube by pouring a
little oil into the tube before installation.
(1) Install new o-ring in pickup tube inlet of oil
pump (Fig. 84).
(2) Position oil pickup tube and filter in rear case.
Be sure pickup filter is seated in case pocket and
that pickup tube is aligned in case notches (Fig. 85).
Be sure hose that connects tube to filter is securely
positioned.
Fig. 81 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 82 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 83 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 84 Pickup Tube O-Ring Installation
1 - O-RING (PUMP PICKUP)
2 - PICKUP TUBE
Fig. 85 Oil Pickup Tube And Filter Position In Rear
Case
1 - FILTER
2 - TUBE AND HOSE
3 - TUBE IN NOTCH
BR/BETRANSFER CASE - NV241LD 21 - 879
TRANSFER CASE - NV241LD (Continued)

(3) Insert oil pickup tube in oil pump and position
pump in rear case (Fig. 86).
(4) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of front case. Keep sealer
bead width to maximum of 3/16 inch. Do not use
excessive amount of sealer as excess will be displaced
into case interior.
(5) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 87). Be sure oil pump and
pickup tube remain in position during case installa-
tion.
(6) Install 4-5 rear case-to front case bolts to hold
rear case in position. Tighten bolts snug but not to
specified torque at this time.
CAUTION: Verify that shift rail (Fig. 88), and case
alignment dowels are seated before installing any
bolts. Case could be cracked if shaft rail or dowels
are misaligned.
(7) Verify that oil pump is aligned and seated on
rear case. Reposition pump if necessary.
(8) Check stud at end of case halves (Fig. 89). If
stud was loosened or came out during disassembly,
apply LoctiteŸ 242 to stud threads and reseat stud
in case.
Fig. 87 Rear Case And Oil Pump Installation
1 - MAINSHAFT
2 - OIL PUMP
3 - REAR CASE
Fig. 88 Shift Rail Seated In Rear Case Bore
1 - REAR CASE
2 - SHIFT RAIL
Fig. 89 Washer Installation On Case Stud And
Dowel Bolts
1 - CASE STUD/BOLT
2 - WASHER
Fig. 86 Positioning Oil Pump In Rear Case
1 - OIL PUMP
2 - REAR CASE
3 - FILTER
4 - PICKUP TUBE
21 - 880 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(9) Apply LoctiteŸ 242 to remainder of rear case-
to-front case bolt threads and install bolts. Be sure
lock washers are used on studs/bolts at case ends.
Tighten bolts, or stud nuts as follows:
²flange head bolts to 47-61 N´m (35-45 ft. lbs.)
²all other bolts/nuts to 27-34 N´m (20-25 ft. lbs.)
(10) Install oil pump retaining ring on mainshaft
(Fig. 90).
(11) Install rear output bearing and snap-ring to
output shaft.
COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 91).
(2) Install companion flange on front shaft (Fig.
92). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
REAR RETAINER AND EXTENSION
(1) Clean mating surfaces of transfer case housing
and the rear retainer of any original gasket material.
(2) Install new rear retainer gasket onto the trans-
fer case housing or rear retainer.
(3) Align and install rear retainer on rear case
(Fig. 93).Fig. 90 Oil Pump Retaining Ring Installation
1 - RETAINING RING
2 - OIL PUMP
Fig. 91 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 92 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
Fig. 93 Rear Retainer Installation
1 - REAR RETAINER
2 - SHIFT RAIL
BR/BETRANSFER CASE - NV241LD 21 - 881
TRANSFER CASE - NV241LD (Continued)

(4) Apply MopartSilicone Sealer to threads of rear
retainer bolts. Then install retainer bolts finger tight.
(5) Install output bearing on mainshaft and seat it
in rear retainer with suitable size pipe tool (Fig. 94).
(6) Install output bearing retaining ring (Fig. 95).
(7) Tighten rear retainer bolts to 27-34 N´m (20-25
ft. lbs.) torque.
(8) Install new seal in rear extension housing seal
with suitable size installer tool.
(9) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(10) Align and install rear extension on retainer
(Fig. 96).(11) Apply MopartSilicone Sealer to threads of
rear extension housing bolts. Then install and
tighten bolts to 27-34 N´m (20-25 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Install rear crossmember.
(4) Remove jack stand from under transmission.
(5) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Connect vacuum harness and vent hose.
(7) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(8) Adjust shift linkage, if necessary.
(9) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(10) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(11) Lower vehicle
Fig. 94 Output Bearing Installation
1 - OUTPUT BEARING
2 - PIPE TOOL
Fig. 95 Output Bearing Retaining Ring Installation
1 - OUTPUT BEARING
2 - RETAINING RING
Fig. 96 Rear Extension Installation
1 - REAR EXTENSION
2 - RETAINER
3 - EXTENSION SEAL
21 - 882 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

SPECIFICATIONS
TRANSFER CASE
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Bolt, Diff. Case 17-27 15-24 -
Plug, Drain/Fill 40-45 30-40 -
Bolt, Extension Housing 35-46 26-34 -
Bolt, Front Brg. Retainer 16-27 12-24 -
Bolt, Case Half 35-46 26-34 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 20-25 -
Bolt, Rear Retainer 35-46 26-34 -
Nuts, Mounting 30-41 20-30 -
Bolts, U-Joint 19 17 -
Vacuum Switch 20-34 15-25 -
BR/BETRANSFER CASE - NV241LD 21 - 883
TRANSFER CASE - NV241LD (Continued)

SPECIAL TOOLS
TRANSFER CASE - NV241LD
Handle, Universal - C-4171
Installer, Seal - 6888
Installer, Bearing - 6953
Installer, Seal - C-4210
Remover, Bushing - 6957
Installer, Bushing - 8157
Installer, Seal - D-163
Installer, Seal - 7884
Installer, Bushing - 5066
21 - 884 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 97).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 98).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
Plug, Extension - C-293-3
Tool Set - L-4518
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 97 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
BR/BETRANSFER CASE - NV241LD 21 - 885
TRANSFER CASE - NV241LD (Continued)