DODGE RAM 2001 Service Repair Manual

FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(4) Remove companion flange nut (Fig. 99). Dis-
card nut after removal. It is not reusable.
(5) Remove companion flange from output shaft.
Use a suitable puller if flange can not be removed by
hand.
(6) Remove companion flange rubber seal from
front output shaft (Fig. 100).
(7) Remove front output shaft seal with suitable
pry tool, or a slide hammer mounted screw.
INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 6888 and Tool Handle C-4171 (Fig.
101) as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore. Once seal is started, con-
tinue tapping seal into bore until installer tool bot-
toms against case.
(c) Remove installer and verify that seal is
recessed the proper amount. Seal should be 2.03 to
2.5 mm (0.080 to 0.100 in.) below top edge of seal
bore in front case (Fig. 102). This is correct final
seal position.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. The
seal could loosen, or become cocked if not seated
to recommended depth.
(2) Install companion flange seal on front shaft
(Fig. 103).Fig. 98 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 99 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - SOCKET
Fig. 100 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 101 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
21 - 886 TRANSFER CASE - NV241LDBR/BE
FLUID (Continued)

(3) Install companion flange on front shaft (Fig.
104). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Remove transfer case shifter knob cap.
(3) Remove nut holding shifter knob to shift lever.
(4) Remove shifter knob.(5) Remove the shift boot from the shifter bezel.
(6) Remove the bolts securing the shifter mecha-
nism to the floor pan along the driver's side of the
transmission tunnel (Fig. 105).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
Fig. 102 Checking Front Output Seal Installation
Depth
1 - CORRECT SEAL DEPTH IS 2.03-2.5 mm (0.080-0.100 in.)
BELOW TOP EDGE OF BORE
2 - FRONT CASE SHAFT BORE
3 - FRONT OUTPUT SEAL
Fig. 103 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 104 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
Fig. 105 Transfer Case Shifter
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
BR/BETRANSFER CASE - NV241LD 21 - 887
FRONT OUTPUT SHAFT SEAL (Continued)

to come out of trunnion, push trunnion out of shift
lever.
(9) Remove the nuts holding the shifter mecha-
nism to the underside of the floor pan.
(10) Separate shift lever mechanism from the vehi-
cle.
INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 106).
(2) Position shift lever on vehicle.
(3) Install nuts to hold shift lever to the underside
of the body.
(4) Install trunnion to shift lever, if necessary.
(5) Install shift rod to trunnion, if necessary.
(6) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(7) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.(8) Lower vehicle.
(9) Install the bolts to hold the shifter mechanism
to the floor pan.
(10) Install the transfer case shifter bezel.
(11) Install the shifter boot and the shifter knob
onto the shifter lever.
(12) Install nut to hold shifter knob to shift lever.
(13) Install shifter knob cap.
(14) Verify transfer case operation.
ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion (Fig.
107).
Fig. 106 Shifter Adjustment
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
Fig. 107 Shift Rod Lock Bolt Location
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
21 - 888 TRANSFER CASE - NV241LDBR/BE
SHIFT LEVER (Continued)

(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion. Lubricate the shift rod
and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H
detent position. The 2H detent position on the trans-
fer case shift arm is the second position from full for-
ward.
(6) Align the adjustment locating hole on the lower
shifter lever with the adjustment channel on the
shifter bracket assembly (Fig. 108).
(7) Insert an appropriately sized pin through into
the adjustment channel and through the locating
hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N´m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans-
fer case shifts into and operates properly in all
ranges.
Fig. 108 Shifter Adjustment Location
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
BR/BETRANSFER CASE - NV241LD 21 - 889
SHIFT LEVER (Continued)

TRANSFER CASE - NV241HD
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241HD
DESCRIPTION..........................890
OPERATION............................892
DIAGNOSIS AND TESTING................892
TRANSFER CASE.....................892
REMOVAL.............................894
DISASSEMBLY..........................894
CLEANING.............................902
INSPECTION...........................902
ASSEMBLY............................904
INSTALLATION..........................919
SPECIFICATIONS........................919
SPECIAL TOOLS........................920EXTENSION HOUSING BUSHING AND SEAL
REMOVAL.............................921
INSTALLATION..........................921
FLUID
STANDARD PROCEDURE.................922
FLUID DRAIN AND REFILL...............922
FRONT OUTPUT SHAFT SEAL
REMOVAL.............................922
INSTALLATION..........................922
SHIFT LEVER
REMOVAL.............................924
INSTALLATION..........................924
ADJUSTMENTS.........................925
TRANSFER CASE - NV241HD
DESCRIPTION
The NV241HD is a part-time transfer case with a
low-range gear system. The transfer case provides
three operating ranges plus a NEUTRAL position.
The low range position provides a gear reduction
ratio of 2.72:1 for increased low speed torque capabil-
ity. Operating ranges are: 2H, 4H, and 4LO.
The synchronizer mechanism consists of a brass
stop ring, synchronizer hub, and the sliding clutch(Fig. 1). The synchronizer components allow the
transfer case to be shifted between the 2H and 4H
operating ranges while the vehicle is in motion.
The gear cases, retainer and extension are all of
aluminum. Drive sprockets and an interconnecting
drive chain are used to transmit engine torque to the
front/rear propeller shafts. The mainshaft, input gear
and front output shaft are supported by ball and nee-
dle bearings.
21 - 890 TRANSFER CASE - NV241HDBR/BE

Fig. 1 NV241HD Transfer Case
1 - FRONT CASE 16 - NEEDLE BEARING
2 - PLANETARY ASSEMBLY 17 - FRONT OUTPUT SHAFT
3 - SUPPORT SLEEVE 18 - SPROCKET
4 - SYNCHRO HUB 19 - ROLLER BEARING
5 - STOP RING 20 - SEAL
6 - REAR CASE 21 - COMPANION FLANGE
7 - OIL PUMP 22 - SECTOR SHAFT
8 - REAR RETAINER 23 - SLIDING CLUTCH
9 - OUTPUT BEARING 24 - SLIDING HUB
10 - REAR EXTENSION 25 - PTO GEAR
11 - SEAL 26 - ANNULUS GEAR
12 - BUSHING 27 - INPUT BEARING RETAINER
13 - SPEEDOMETER GEAR 28 - SEAL
14 - DRIVE SPROCKET 29 - INPUT GEAR
15 - CHAIN 30 - INPUT BEARING
BR/BETRANSFER CASE - NV241HD 21 - 891
TRANSFER CASE - NV241HD (Continued)

PTO CAPABILITY
The NV241HD transfer case has power take-off
capability. A PTO gear permanently attached to the
planetary carrier, and a removable PTO cover are
provided for this purpose.
IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
OPERATING RANGES
Transfer case operating ranges are:
²2H (2-wheel drive)
²4H (4-wheel drive)
²4LO (4-wheel drive low range)The 2H range is for use on any road surface at any
time.
The 4H and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is covered by
ice and snow or other loose, slippery material.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
A front axle disconnect system is used to achieve
two-wheel drive mode. The axle disconnect vacuum
motor is actuated by a vacuum switch on the transfer
case. The switch is operated by the transfer case
range rod.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The synchronizer components allow the transfer
case to be shifted between the 2H and 4H operating
ranges while the vehicle is in motion. The vehicle
must have the transmission placed in NEUTRAL, or
the clutch depressed in the case of a manual trans-
mission, and be moving less than 2-3 MPH when
shifting into the 4L operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
Fig. 2 Transfer Case Identification Tag - Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 892 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

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.
BR/BETRANSFER CASE - NV241HD 21 - 893
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).
Fig. 3 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - SOCKET
Fig. 4 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 5 Shift Lever Removal
1 - SHIFT LEVER
2 - NUT/WASHER
21 - 894 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

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
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
BR/BETRANSFER CASE - NV241HD 21 - 895
TRANSFER CASE - NV241HD (Continued)