Dodge Dakota (ND). Manual — part 1124
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (6). 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 (1) 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 (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also replace
the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks (1, 2) and mode fork
shift rail (2). Minor nicks on the shift rail can be
smoothed with 320-400 grit emery cloth.
Input Gear and Carrier Components
1 - PLANETARY CARRIER
4 - CARRIER LOCK RING
2 - REAR THRUST WASHER
5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER
6 - INPUT GEAR
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Inspect the shift fork wear pads (3, 4). The mode and
range fork pads are serviceable and can be replaced
if necessary.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR RETAINER AND EXTENSION HOUSING
Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the
bearing bore. Clean the retainer sealing surfaces with a scraper and 3M™ all purpose cleaner. This will ensure
proper adhesion of the sealer during reassembly.
Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or
damage.
FRONT OUTPUT SHAFT/FLANGE/DRIVE CHAIN
Check condition of the seal contact surfaces on the companion flange slinger. This surface must be clean and
smooth to ensure proper seal life. Replace the flange nut and seal washer as neither part should be reused.
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an
oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the
shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if
any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, dis-
torted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear is
only serviced as part of the front case. If the gear is
damaged, it will be necessary to replace the gear and
front case as an assembly. Do not attempt to remove
the gear (2)
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TRANSFER CASE - NV233
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FRONT/REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and damage. Replace the input retainer seal; do not reuse it.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil
T
stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
Lubricate transfer case components with Mopar
T
ATF +4, Automatic Transmission Fluid or petroleum jelly (where
indicated) during assembly.
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BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make
sure replacement bearings do not block the holes.
1. Remove the front output shaft seal (1) from case
with pry tool (2).
2. Remove bearing retaining ring with screwdriver.
3. Remove bearing with Tool Handle C-4171 (2) and
Tool 5065 (3).
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TRANSFER CASE - NV233
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