DODGE RAM 2002 Service Repair Manual

Check condition of the shift fork pads (Fig. 39).
The pads should be replaced if cracked, worn, or
loose (won't stay on fork).
The shift forks, clutch and sleeve should all be
checked for wear, cracks, or any type of damage (Fig.
40). The shift sector shaft and detents should be
inspected for wear. The mode fork and shift rail are a
one-piece unit. If either part is damaged, replace the
fork and rail as an assembly. Replace the shift rail
cup and spring if they exhibit wear.
Inspect the planetary thrust washers (Fig. 41)
carefully for wear or damage. Replace both washers
if necessary.
The planetary carrier cannot be disassembled. It
must be serviced as an assembly if damaged. Check
condition of the pinion teeth and PTO gear teeth. If
pinion tooth wear is evident, it will also be necessary
to check condition of the annulus gear teeth.
Fig. 38 Mainshaft Components
1 - DRIVE SPROCKET 5 - STRUTS
2 - STOP RING 6 - SYNCHRO SPRINGS
3 - SYNCHRO HUB 7 - MAINSHAFT
4 - RETAINING RING
Fig. 39 Shift Fork Pads
1-PADS
2-PADS
3 - RANGE FORK
4 - MODE FORK
21 - 478 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

Fig. 40 Shift Fork Components
1 - SUPPORT SLEEVE 5 - MODE FORK AND SHIFT RAIL
2 - RANGE FORK 6 - SPRING
3 - SHIFT SECTOR 7 - CUP
4 - POPPET PLUNGER, SPRING, SCREW 8 - SLIDING CLUTCH
Fig. 41 Planetary And Input Gear Components
1 - LOCK RING 6 - RETAINING RING
2 - THRUST WASHERS 7 - SUPPORT SLEEVE
3 - PLANETARY CARRIER 8 - INPUT GEAR
4 - PTO GEAR 9 - RETAINING RING
5 - BEARING
BR/BETRANSFER CASE - NV241HD 21 - 479
TRANSFER CASE - NV241HD (Continued)

ASSEMBLY
BEARINGS AND SEALS
(1) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing from case from inside annu-
lus gear opening (Fig. 42).
(2) Install locating ring on new bearing.
(3) Position case so that the forward end is facing
upward.
(4) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing into case. The bearing
locating ring must be fully seated on case (Fig. 43).
(5) Using Installer 6953, remove front output shaft
bearing.
(6) Start front shaft output bearing in case (Fig.
44). Then seat bearing with Handle C-4171 and
Installer 6953.
(7) Install front output bearing retaining ring.
(8) Install new front output seal in front case with
Installer Tool 6888 (Fig. 45) and Tool Handle C-4171
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. 46). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
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. This is correct final seal posi-
tion.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. Theseal could loosen, or become cocked if not seated
to recommended depth.
(9) Remove seal from front bearing retainer with
suitable pry tool.
Fig. 42 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 43 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 44 Front Output Bearing Installation
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
21 - 480 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(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).
Fig. 45 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
Fig. 46 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. 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
BR/BETRANSFER CASE - NV241HD 21 - 481
TRANSFER CASE - NV241HD (Continued)

(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).(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. 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
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
21 - 482 TRANSFER CASE - NV241HDBR/BE
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.
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
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
BR/BETRANSFER CASE - NV241HD 21 - 483
TRANSFER CASE - NV241HD (Continued)

(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).(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.
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)
Fig. 59 Retaining Ring Installation
1 - RETAINING RING
Fig. 60 Planetary/Input Gear Assembly Installation
1 - WOOD/RUBBER HAMMER HANDLE
2 - PLANETARY ASSEMBLY
21 - 484 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(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).(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).
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
Fig. 63 Input Bearing Retainer Installation
1 - FRONT CASE
2 - INPUT BEARING RETAINER
Fig. 64 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
BR/BETRANSFER CASE - NV241HD 21 - 485
TRANSFER CASE - NV241HD (Continued)

(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.
(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.
(6) Install sliding clutch (sleeve) on synchronizer
hub (Fig. 71).
Fig. 65 Synchronizer Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKETFig. 66 Installing First Synchronizer Strut And
Spring
1 - FIRST STRUT
2 - SYNCHRO HUB
3 - SPRING
Fig. 67 Synchronizer Spring Installation
1 - STRUT SHOULDER
2 - SPRING (SEATED IN STRUT)
3 - HUB
21 - 486 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

Fig. 68 Correct Position Of Struts And Springs
1 - STRUTS
2 - SPRING
Fig. 69 Synchronizer Hub Installation
1 - SYNCHRO HUB (SHOULDER SIDE DOWN)
2 - STOP RING AND SPROCKET
Fig. 70 Synchronizer Hub Retaining Ring
Installation
1 - SNAP-RING PLIERS
2 - SYNCHRO HUB
3 - HUB RETAINING RING
Fig. 71 Sliding Clutch Installation
1 - SLIDING CLUTCH
2 - SYNCHRO HUB
BR/BETRANSFER CASE - NV241HD 21 - 487
TRANSFER CASE - NV241HD (Continued)