DODGE RAM 2002 Service Repair Manual

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.
(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).
Fig. 72 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTH NOT ALIGNED WITH STRUT
4 - STRUT
Fig. 73 Shift Sector Installation
1 - SHIFT SECTOR
2 - SECTOR SHAFT
Fig. 74 Assembling Range Fork And Sliding Hub
1 - RANGE FORK
2 - SLIDING HUB
21 - 488 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(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).
(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.
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
Fig. 78 Installing Mainshaft And Mode Fork
Assembly
1 - MAINSHAFT AND MODE FORK ASSEMBLY
2 - SHIFT RAIL
3 - RANGE FORK
BR/BETRANSFER CASE - NV241HD 21 - 489
TRANSFER CASE - NV241HD (Continued)

(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.
(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.).
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
Fig. 82 Poppet Plunger And Spring Installation
1 - POPPET PLUNGER AND SPRING
21 - 490 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

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.
(6) Install front sprocket retaining ring (Fig. 86).
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
Fig. 86 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
BR/BETRANSFER CASE - NV241HD 21 - 491
TRANSFER CASE - NV241HD (Continued)

(7) Realign sliding clutch on synchronizer hub if
necessary. Press synchronizer struts inward to ease
realignment. Be sure mainshaft is fully seated before
proceeding.
(8) Install spring and cup on shift rail (Fig. 87).
(9) Insert magnet in front case pocket (Fig. 88).
OIL PUMP AND REAR CASE
Lubricate the oil pump components before installa-
tion. 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. 89).
(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. 90).
Be sure hose that connects tube to filter is securely
positioned.
(3) Insert oil pickup tube in oil pump and position
pump in rear case (Fig. 91).(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. 92). 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. 93), and case
alignment dowels are seated before installing any
bolts. Case could be cracked if shaft rail or dowels
are misaligned.
Fig. 87 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 88 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 89 Pickup Tube O-Ring Installation
1 - O-RING (PUMP PICKUP)
2 - PICKUP TUBE
Fig. 90 Oil Pickup Tube And Filter Position In Rear
Case
1 - FILTER
2 - TUBE AND HOSE
3 - TUBE IN NOTCH
21 - 492 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(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. 94). 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 rear output bearing and snap-ring to
output shaft.
Fig. 91 Positioning Oil Pump In Rear Case
1 - OIL PUMP
2 - REAR CASE
3 - FILTER
4 - PICKUP TUBE
Fig. 92 Rear Case And Oil Pump Installation
1 - MAINSHAFT
2 - OIL PUMP
3 - REAR CASE
Fig. 93 Shift Rail Seated In Rear Case Bore
1 - REAR CASE
2 - SHIFT RAIL
Fig. 94 Washer Installation On Case Stud And
Dowel Bolts
1 - CASE STUD/BOLT
2 - WASHER
BR/BETRANSFER CASE - NV241HD 21 - 493
TRANSFER CASE - NV241HD (Continued)

COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 95).
(2) Install companion flange on front shaft (Fig.
96). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
EXTENSION HOUSING AND PTO COVER
(1) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of extension housing. 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 pump.
(2) Position extension housing over output shaft.
(3) Spread extension housing retaining ring and
seat extension housing on rear case. Verify that the
retaining ring is seated in output shaft rear bearing.
(4) Install retaining ring access cover.
(5) Apply MopartSilicone Sealer, or equivalent, to
threads of extension housing bolts. Then install bolts
finger tight.
(6) Tighten extension housing bolts to 27-34 N´m
(20-25 ft. lbs.) torque.
(7) Apply MopartSilicone Sealer to mating surface
of PTO cover and to cover bolt shanks and underside
of bolt heads. 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. 95 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 96 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
21 - 494 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (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 -
SPECIAL TOOLS
TRANSFER CASE - NV241HD
Handle, Universal - C-4171
Installer, Seal - 6888
Installer, Bushing - 8156
Remover, Bushing - 8155
Installer, Seal - 8154
BR/BETRANSFER CASE - NV241HD 21 - 495
TRANSFER CASE - NV241HD (Continued)

Installer, Bearing - 6953
Installer, Seal - 7884
Plug, Extension - C-293-3
Installer, Seal - C-4210
Installer, Bearing - 5062
Installer, Bushing - 5066
Installer, Pump Housing Seal - 7888
Remover, Bearing - L-4454
Cup - 8148
21 - 496 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (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 8155, remove bushing from
extension housing (Fig. 97).
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 8156, drive bushing into hous-
ing until installer seats against case (Fig. 98).
(4) Using Installer 8154, install seal in extension
housing (Fig. 99).
(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/
REFILL
(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.
Fig. 97 Extension Housing Bushing Removal
1 - REMOVER 8155
2 - EXTENSION HOUSING BUSHING
Fig. 98 Extension Housing Bushing Installation
1 - EXTENSION HOUSING BUSHING
2 - INSTALLER 8156
Fig. 99 Install Extension Housing Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8154
BR/BETRANSFER CASE - NV241HD 21 - 497