Transmission fluid DODGE RAM 2003 Service Repair Manual

(8) Install the drive sprocket retaining ring (Fig.
61) onto the output shaft.
(9) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 62). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(10) Install the shift sector support (Fig. 63).
Tighten the sector support to 27-42 N´m (20-30
ft.lbs.).(11) Assemble and install range fork and hub (Fig.
64). 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.
(13) Install the range fork retaining ring.
Fig. 61 Install The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 62 Install Shift Sector
1 - SHIFT SECTOR
Fig. 63 Install Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
Fig. 64 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
DRTRANSFER CASE - NV241 GENII 21 - 609
TRANSFER CASE - NV241 GENII (Continued)

REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) 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.
(3) Align and install rear extension on retainer
(Fig. 80).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 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) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.
(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 40-45 30-40 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 614 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

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 transfer case can 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 transmission, and be moving less
than 2-3 MPH when shifting into and out of the 4L
operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
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.
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, 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, Automatic
Transmission fluid.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 624 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(17) Install the rear output shaft bearing (Fig. 55)
into the rear case using Installer 8152 and Handle
C-4171.
(18) Install the rear output shaft bearing snap-
ring into the rear case half.
INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers with rec-
ommended transmission fluid.
(2) Install bottom thrust washer (Fig. 56) in low
range gear planetary. Be sure washer tabs are prop-
erly aligned in gear notches.(3) Install input gear in low range gear (Fig. 57).
Be sure input gear is fully seated.
(4) Install remaining thrust washer (Fig. 58) in
low range gear and on top of input gear.
Fig. 56 Install Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
Fig. 58 Install Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 55 Install Rear Output Shaft Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8152
Fig. 57 Install Input Gear From Planetary
1 - INPUT GEAR
2 - LOW RANGE PLANETARY
21 - 640 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Coat the interior of the drive sprocket hub with
ATF+4 and install the drive sprocket drive hub (Fig.
63) onto the mainshaft.(3) Install the mode hub (Fig. 64) onto the main-
shaft.
(4) Install the mode hub retaining ring (Fig. 65)
onto the mainshaft.
(5) Install the clutch gear (Fig. 66) onto the output
shaft. Verify that the pointed ends of the clutch gear
teeth are pointing to the front of the mainshaft.
Fig. 64 Install Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 63 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 65 Install Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
Fig. 66 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
21 - 642 TRANSFER CASE - NV271DR
TRANSFER CASE - NV271 (Continued)

(6) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 67). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(7) Apply LoctiteŸ 242, or equivalent, to the
threads of the sector support to replentish the factory
applied patch. Install the shift sector support.
Tighten the sector support with Socket 9033 to 27-34
N´m (20-25 ft.lbs.).
(8) Assemble and install range fork and hub (Fig.
68). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(9) Align and insert range fork pin in shift sector
slot.
(10) Install mode fork and shift rail onto the mode
sleeve.(11) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 69).
(12) Install mainshaft into the transfer case (Fig.
70). Guide mainshaft through the mode and range
sleeves and into the input gear.
Fig. 67 Install Shift Sector
1 - SHIFT SECTOR
Fig. 68 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 69 Install Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 70 Install Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
DRTRANSFER CASE - NV271 21 - 643
TRANSFER CASE - NV271 (Continued)

(7) Install the front companion flange onto the
front output shaft.
(8) Install two bolts 180É apart into the front out-
put shaft companion flange.
(9) Place holder over the bolts and against the
companion flange (Fig. 90).
(10) Install a new front companion flange nut.
Tighten the companion flange nut to 176-271 N´m
(130-200 ft.lbs.).
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) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV271
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Fig. 90 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
DRTRANSFER CASE - NV271 21 - 649
TRANSFER CASE - NV271 (Continued)

IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID 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
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range sleeve.
The front output shaft is operated by a drive chain
that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is engaged/disengaged
by the mode fork, which operates the mode sleeve
and hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV243 21 - 659
TRANSFER CASE - NV243 (Continued)

INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 51)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 51). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 52). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 53).
(8) Install a new input gear seal using Installer
8841 and Handle C-4171.
Fig. 51 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 52 Install Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
Fig. 53 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
DRTRANSFER CASE - NV243 21 - 673
TRANSFER CASE - NV243 (Continued)

SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install the mode hub (Fig. 54) onto the output
shaft.
(3) Install the mode hub retaining ring (Fig. 55)
onto the output shaft.(4) Install the sprocket hub (Fig. 56) onto the out-
put shaft.
(5) Install the clutch gear (Fig. 57) onto the output
shaft.
(6) Install the drive sprocket (Fig. 58) onto the out-
put shaft.
Fig. 54 Install Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 55 Install Mode Hub Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 56 Install Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 57 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
21 - 674 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)