lock DODGE RAM 2001 Service Repair Manual

(8) Clean gasket sealer residue from retainer and
inspect retainer for cracks or other damage.
(9) Applya3mm(1/8 in.) bead of MopartGasket
Maker, or equivalent silicone adhesive, to sealing
surface of retainer.
(10) Align cavity in seal retainer with fluid return
hole in front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying MoparTGas-
ket Maker, or equivalent silicone adhesive sealer.
Seal failure and fluid leak can result.
(11) Install bolts to hold retainer to transfer case
(Fig. 59). Tighten to 21 N´m (16 ft. lbs.) of torque.
SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install drive sprocket on mainshaft (Fig. 60).
(3) Install brass stop ring on drive sprocket (Fig.
61).
(4) Install 3 synchro struts and 2 springs in hub as
follows:
(a) Insert first strut in hub (Fig. 62). Strut
shoulders rest (and slide) on sides hub slot as
shown.
(b) Insert hooked end of first spring in center of
strut to secure it. Then work spring into hub (Fig.
63).
Fig. 58 Install Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 59 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 60 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
Fig. 61 Synchro Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKET
21 - 838 TRANSFER CASE - NV231HDBR/BE
TRANSFER CASE - NV231HD (Continued)

(6) Install synchro hub retaining ring (Fig. 66). Be
sure ring is fully seated before proceeding.
(7) Install sliding clutch (sleeve) on synchro hub
(Fig. 67).
CAUTION: The sliding clutch must be correctly
positioned to ensure proper shifting. Position the
clutch on the hub so a clutch spline is centeredover each strut as shown (Fig. 68). If the clutch is
installed so a gap between splines is aligned with
one or more struts, gear clash will result.
(8) 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.
(9) Lubricate mainshaft components with trans-
mission fluid.
(10) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 69). 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.
70). 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.
Fig. 66 Synchro Hub Retaining Ring Installation
1 - SNAP-RING PLIERS
2 - SYNCHRONIZER HUB
3 - HUB RETAINING RING
Fig. 67 Sliding Clutch Installation
1 - SLIDING CLUTCH
2 - SYNCHRONIZER HUB
Fig. 68 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTHNOTALIGNED WITH STRUT
4 - STRUT
21 - 840 TRANSFER CASE - NV231HDBR/BE
TRANSFER CASE - NV231HD (Continued)

(15) Install vacuum/indicator switch (Fig. 73).
Tighten switch to 20-34 N´m (15-25 ft. lbs.) torque.
Install new O-ring on switch beforehand, if necessary.
(16) Install new sector shaft O-ring and O-ring
retainer in sector shaft bore (Fig. 74). Lubricate
O-ring with transmission fluid or petroleum jelly
after installation.
(17) Install shift lever on sector shaft (Fig. 75).
(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.(19) Install poppet plunger and spring (Fig. 76).
(20) Install new O-ring on poppet screw and install
screw in front case (Fig. 77). Tighten screw to 16-24
N´m (12-18 ft. lbs.).
Fig. 73 Vacuum/Indicator Switch Installation
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 74 Sector Shaft O-Ring And Retainer Installation
1 - SECTOR SHAFT BORE
2 - O-RING
3 - O-RING RETAINER
Fig. 75 Shift Lever Installation
1 - SHIFT LEVER
2 - NUT/WASHER
Fig. 76 Poppet Plunger And Spring Installation
1 - POPPET PLUNGER AND SPRING
Fig. 77 O-Ring Installation On Poppet Plunger
Screw
1 - O-RING
2 - PLUNGER SCREW
21 - 842 TRANSFER CASE - NV231HDBR/BE
TRANSFER CASE - NV231HD (Continued)

(5) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 86). 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. 87), 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. 88). If
stud was loosened or came out during disassembly,
apply LoctiteŸ 242 to stud threads and reseat stud
in case.
(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. 89).
Fig. 86 Rear Case And Oil Pump Installation
1 - MAINSHAFT
2 - OIL PUMP
3 - REAR CASE
Fig. 87 Shift Rail Seated In Rear Case Bore
1 - REAR CASE
2 - SHIFT RAIL
Fig. 88 Washer Installation On Case Stud And
Dowel Bolts
1 - CASE STUD/BOLT
2 - WASHER
Fig. 89 Oil Pump Retaining Ring Installation
1 - RETAINING RING
2 - OIL PUMP
BR/BETRANSFER CASE - NV231HD 21 - 845
TRANSFER CASE - NV231HD (Continued)

(6) Install output bearing retaining ring (Fig. 94).
(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. 95).(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 Retaining Ring Installation
1 - OUTPUT BEARING
2 - RETAINING RING
Fig. 95 Rear Extension Housing Installation
1 - REAR EXTENSION
2 - RETAINER
3 - EXTENSION SEAL
BR/BETRANSFER CASE - NV231HD 21 - 847
TRANSFER CASE - NV231HD (Continued)

INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 101). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange seal on front shaft
(Fig. 102).
(3) Install companion flange on front shaft (Fig.
103). 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. 104).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
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.
Fig. 101 Front Output Seal Installation
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 102 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 103 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
21 - 852 TRANSFER CASE - NV231HDBR/BE
FRONT OUTPUT SHAFT SEAL (Continued)

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. 105).
(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.
106).
Fig. 104 Transfer Case Shifter
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
Fig. 105 Shifter Adjustment
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
Fig. 106 Shift Rod Lock Bolt Location
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
BR/BETRANSFER CASE - NV231HD 21 - 853
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. 107).(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. 107 Shifter Adjustment Location
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
21 - 854 TRANSFER CASE - NV231HDBR/BE
SHIFT LEVER (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.
REAR EXTENSION, RETAINER, AND REAR CASE
(1) Remove rear extension bolts (Fig. 2).(2) Remove rear extension housing (Fig. 3). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 4).
Fig. 2 Rear Extension Bolt Removal
1 - SOCKET
2 - REAR EXTENSION
Fig. 3 Rear Extension Housing Removal
1 - SEAL
2 - REAR EXTENSION HOUSING
3 - REAR RETAINER
Fig. 4 Removing Output Bearing Retaining Ring
1 - OUTPUT BEARING
2 - RETAINING RING
3 - REAR RETAINER
21 - 858 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket (Fig. 41). Minor nicks and
scratches can be smoothed with an oilstone, however,
replace any part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches canbe smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
Inspect the spline teeth on the synchronizer hub. 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.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 42). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
Fig. 41 Mainshaft Components
1 - DRIVE SPROCKET 5 - STRUTS
2 - STOP RING 6 - SYNCHRONIZER SPRINGS
3 - SYNCHRONIZER HUB 7 - MAINSHAFT
4 - RETAINING RING
Fig. 40 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
BR/BETRANSFER CASE - NV241LD 21 - 867
TRANSFER CASE - NV241LD (Continued)