clutch DODGE RAM 2003 Service Repair Manual

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
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 transfer case position
sensor connector.
(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) Mark front and rear propeller shafts for assem-
bly reference.(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) 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.
DRTRANSFER CASE - NV241 GENII 21 - 593
TRANSFER CASE - NV241 GENII (Continued)

(3) Remove drive sprocket (Fig. 28) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 29) and hub (Fig.
30) from the output shaft.
(5) Remove the mode hub retaining ring (Fig. 31)
from the output shaft.
(6) Remove the mode hub (Fig. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.
(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
Fig. 28 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 31 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
21 - 600 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

(4) Install the sprocket hub (Fig. 57) onto the out-
put shaft.
(5) Install the clutch gear (Fig. 58) onto the output
shaft.
(6) Install the drive sprocket (Fig. 59) onto the out-
put shaft.
(7) Install the drive sprocket thrust washer (Fig.
60) onto the output shaft.
Fig. 60 Install Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
Fig. 57 Install Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 58 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 59 Install Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
21 - 608 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)

Condition Possible Cause Correction
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
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 transfer case position
sensor connector.
(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) Mark front and rear propeller shafts for assem-
bly reference.
(9) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)(10) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) 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.
COMPANION FLANGE AND EXTENSION HOUSING
(1) Install two bolts 180É apart into the front out-
put shaft companion flange.
(2) Place holder over the bolts and against the
companion flange (Fig. 3).
(3) Remove and discard the front companion flange
nut.
DRTRANSFER CASE - NV271 21 - 625
TRANSFER CASE - NV271 (Continued)

(12) Remove range fork and hub as an assembly
(Fig. 27). Note fork position for installation reference.
(13) Remove shift sector (Fig. 28).MAINSHAFT
(1) Remove the clutch gear (Fig. 29) from the out-
put shaft.
(2) Remove the mode hub retaining ring (Fig. 30)
from the mainshaft.
Fig. 30 Remove Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
Fig. 27 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 28 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
21 - 632 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)

Condition Possible Cause Correction
Transfer case noisy while in, or
jumps out of, 4LO mode.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,1) Operate vehicle in 2WD mode on
dry surfaces.
REMOVAL
(1) Shift transfer case into 2WD.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shafts for align-
ment reference.
(5) Support transmission with jack stand.
(6) Remove the transfer case skid plate, if
equipped.
(7) Disconnect front and rear propeller shafts at
transfer case.
(8) Disconnect transfer case shift motor and mode
sensor wire connectors.
(9) Disconnect transfer case vent hose.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission (Fig. 2).
(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove 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.
Fig. 2 Remove Transfer Case - Typical
1 - TRANSMISSION
2 - TRANSFER CASE
3 - MODE SENSOR CONNECTOR
21 - 660 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
25) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
26) from the output shaft.
(3) Remove drive sprocket (Fig. 27) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 28) and hub (Fig.
29) from the output shaft.
Fig. 25 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 26 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
Fig. 27 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 28 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 29 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
21 - 666 TRANSFER CASE - NV243DR
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)