DODGE RAM 2001 Service Repair Manual

(9) Remove seal from front bearing retainer with
suitable pry tool.
(10) Install new oil seal in front bearing retainer
with Installer 7884 (Fig. 47).
(11) Remove seal from oil pump with suitable pry
tool.
(12) Install new seal in oil pump with Installer
7888 (Fig. 48).(13) Inspect carrier needle bearing. If bearing is
worn, rough, or damaged in any way, remove it with
a brass punch and hammer (Fig. 49).
(14) Install new needle bearing in planetary car-
rier (Fig. 50). Use Handle C±4171 and Installer 5062
to install bearing.
(15) 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. 51).
(16) Install new pilot bearing with Plug C-293-3.
(17) Remove the output shaft rear bearing with
the screw and jaws from Remover L-4454 and Cup
8148 (Fig. 52).
Fig. 47 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 48 Install Oil Pump Seal
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
Fig. 49 Carrier Needle Bearing Removal
1 - BRASS PUNCH
2 - CARRIER NEEDLE BEARING
Fig. 50 Planetary Carrier Needle Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5062
3 - CARRIER BEARING
21 - 906 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(18) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 53). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 54).
Fig. 51 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 52 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 53 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 54 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
BR/BETRANSFER CASE - NV241HD 21 - 907
TRANSFER CASE - NV241HD (Continued)

INPUT AND PLANETARY GEAR
(1) Lubricate planetary components with transmis-
sion fluid.
(2) Install first thrust washer in carrier (Fig. 55).
Lube washer with petroleum jelly before installation.
(3) Support carrier with wood blocks under PTO
gear (Fig. 56).
(4) Install support sleeve in planetary carrier. Be
sure sleeve is seated.(5) Install input gear in planetary carrier (Fig. 57).
(6) Install second thrust washer in planetary car-
rier. Be sure washer tabs are seated in carrier slots.
(7) Install lock ring (Fig. 58).
Fig. 55 Thrust Washer Installation
1 - THRUST WASHER
2 - TABS IN SLOTS
Fig. 56 Support Sleeve Installation
1 - PLANETARY
2 - SUPPORT SLEEVE
3 - WOOD BLOCKS
Fig. 57 Input Gear And Thrust Washer Installation
1 - INPUT GEAR
2 - THRUST WASHER
3 - TABS IN SLOTS
Fig. 58 Lock Ring Installation
1 - LOCK RING (BE SURE TABS ARE SEATED IN SLOTS)
21 - 908 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(8) Install retaining ring (Fig. 59).
INPUT AND PLANETARY GEAR
(1) Lubricate planetary pinions and annulus gear
with transmission fluid.
(2) Install planetary/input gear assembly in case
(Fig. 60).
(3) Start planetary pinions in low range annulus
gear. Then tap PTO gear, with hammer handle to
seat planetary pinions in annulus gear.
(4) Install retaining ring on input gear (Fig. 61).
(5) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of input retainer. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could be dis-
placed into oil channel and feed hole in case.(6) Align oil channel in retainer with oil feed hole
in front case (Fig. 62).
(7) Install retainer on input gear shaft and front
case (Fig. 63).
Fig. 59 Retaining Ring Installation
1 - RETAINING RING
Fig. 60 Planetary/Input Gear Assembly Installation
1 - WOOD/RUBBER HAMMER HANDLE
2 - PLANETARY ASSEMBLY
Fig. 61 Installing Input Gear Retaining Ring
1 - INPUT BEARING RETAINING RING
2 - SNAP-RING PLIERS
3 - INPUT GEAR
Fig. 62 Aligning Retainer Oil Channel and Case
Feed Holes
1 - FEED HOLE
2 - FRONT CASE
3 - FEED CHANNEL
4 - BEARING RETAINER
BR/BETRANSFER CASE - NV241HD 21 - 909
TRANSFER CASE - NV241HD (Continued)

(8) Apply MopartSilicone Sealer to threads of
input retainer bolts. Then install and tighten bolts to
27-34 N´m (20-25 ft. lbs.) torque.
MAINSHAFT
(1) Install drive sprocket on mainshaft (Fig. 64).
(2)
Install brass stop ring on drive sprocket (Fig. 65).
(3) Install 3 synchronizer struts and 2 springs in
hub as follows:
(a) Insert first strut in hub (Fig. 66). Strut
shoulders rest (and slide) on sides hub slot as
shown.
Fig. 65 Synchronizer Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKET
Fig. 66 Installing First Synchronizer Strut And
Spring
1 - FIRST STRUT
2 - SYNCHRONIZER HUB
3 - SPRING
Fig. 63 Input Bearing Retainer Installation
1 - FRONT CASE
2 - INPUT BEARING RETAINER
Fig. 64 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
21 - 910 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(b) Insert hooked end of first spring in center of
strut to secure it. Then work spring into hub (Fig.
67).
(c) Press spring inward and insert last two
struts in hub slots. Be sure spring is positioned
under struts to properly secure them (Fig. 68).
(d) Turn hub over and install remaining spring
in hub. Position hooked end of second spring oppo-
site the first spring's hooked end.
(4) Install assembled synchronizer hub on main-
shaft (Fig. 69). Hub has shoulder on one side which
goes toward sprocket (rear of shaft). Flat side of hub
faces front of shaft.
(5) Install synchronizer hub retaining ring (Fig.
70). Be sure ring is fully seated before proceeding.
Fig. 67 Synchronizer Spring Installation
1 - STRUT SHOULDER
2 - SPRING (SEATED IN STRUT)
3 - HUB
Fig. 68 Correct Position Of Struts And Springs
1 - STRUTS
2 - SPRING
Fig. 69 Synchronizer Hub Installation
1 - SYNCHRONIZER HUB (SHOULDER SIDE DOWN)
2 - STOP RING AND SPROCKET
Fig. 70 Synchronizer Hub Retaining Ring
Installation
1 - SNAP-RING PLIERS
2 - SYNCHRONIZER HUB
3 - HUB RETAINING RING
BR/BETRANSFER CASE - NV241HD 21 - 911
TRANSFER CASE - NV241HD (Continued)

(6) Install sliding clutch (sleeve) on synchronizer
hub (Fig. 71).
CAUTION: The sliding clutch must be correctly
positioned to ensure proper shifting. Position the
clutch on the hub so a clutch spline is centered
over each strut as shown (Fig. 72). If the clutch is
installed so a gap between splines is aligned with
one or more struts, gear clash will result.
SHIFT FORKS AND MAINSHAFT
(1) Support front case on wood blocks so case inte-
rior is facing up. Place blocks between mounting
studs on forward surface of case. Be sure blocks will
not interfere with input gear installation.
(2) Lubricate mainshaft components with trans-
mission fluid.
(3) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 73). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
Fig. 71 Sliding Clutch Installation
1 - SLIDING CLUTCH
2 - SYNCHRONIZER HUB
Fig. 72 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTHNOTALIGNED WITH STRUT
4 - STRUT
Fig. 73 Shift Sector Installation
1 - SHIFT SECTOR
2 - SECTOR SHAFT
21 - 912 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(4) Assemble range fork and sliding hub (Fig. 74).
Then install fork and hub in case. Seat hub on sup-
port sleeve and seat range fork pin in shift sector slot
(Fig. 75).
(5) Install sliding hub retaining ring (Fig. 76). Be
sure ring is fully seated before proceeding.
(6) Install mode fork and shift rail in sliding clutch
(Fig. 77).
Fig. 74 Assembling Range Fork And Sliding Hub
1 - RANGE FORK
2 - SLIDING HUB
Fig. 75 Seating Range Fork And Hub
1 - RANGE FORK
2 - RANGE FORK PIN
3 - SECTOR SLOT
4 - SHIFT SECTOR
Fig. 76 Sliding Hub Retaining Ring Installation
1 - RETAINING RING
2 - RANGE FORK
3 - SLIDING HUB
Fig. 77 Assembling Mode Fork And Mainshaft
1 - SLIDING CLUTCH
2 - MODE FORK AND SHIFT RAIL
BR/BETRANSFER CASE - NV241HD 21 - 913
TRANSFER CASE - NV241HD (Continued)

(7) Install mainshaft/mode fork assembly (Fig. 78).
Guide mainshaft through hub and into input gear
and shift rail through range fork and into case bore.
(8) Install new o-ring on vacuum/indicator switch,
if necessary. Install vacuum/indicator switch (Fig.
79). Tighten switch to 20-34 N´m (15-25 ft. lbs.)
torque.
(9) Install new sector shaft o-ring and o-ring
retainer in sector shaft bore (Fig. 80). Lubricate
o-ring with transmission fluid or petroleum jelly after
installation.(10) Install shift lever on sector shaft (Fig. 81).
(11) 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. 78 Installing Mainshaft And Mode Fork
Assembly
1 - MAINSHAFT AND MODE FORK ASSEMBLY
2 - SHIFT RAIL
3 - RANGE FORK
Fig. 79 Vacuum/Indicator Switch Installation
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 80 Sector Shaft O-Ring And Retainer
Installation
1 - SECTOR SHAFT BORE
2 - O-RING
3 - O-RING RETAINER
Fig. 81 Shift Lever Installation
1 - SHIFT LEVER
2 - NUT/WASHER
21 - 914 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(12) Install poppet plunger and spring (Fig. 82).
(13) Install new o-ring on poppet screw and install
screw in front case (Fig. 83). 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. 84).
(2) Insert front sprocket in drive chain (Fig. 85).
(3) Install drive chain around mainshaft sprocket
(Fig. 85). 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 sliding clutch were unseated
during chain installation, align and reseat mainshaft
in input gear and hub. Then reseat synchronizer hub
in sliding clutch. Press synchronizer struts inward to
ease clutch back onto hub.
Fig. 82 Poppet Plunger And Spring Installation
1 - POPPET PLUNGER AND SPRING
Fig. 83 O-Ring Installation On Poppet Plunger
Screw
1 - O-RING
2 - PLUNGER SCREW
Fig. 84 Front Output Shaft Installation
1 - FRONT OUTPUT SHAFT
2 - BEARING
Fig. 85 Drive Chain And Front Sprocket Installation
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
3 - FRONT SPROCKET
4 - FRONT SHAFT
BR/BETRANSFER CASE - NV241HD 21 - 915
TRANSFER CASE - NV241HD (Continued)