Dodge Durango (HB). Manual — part 1351
4. Remove the differential assembly (1) from the
mainshaft (2).
DIFFERENTIAL
1. Remove the mode hub and mode hub retainer (2)
from the differential assembly (1).
2. Remove the mode hub retainer (1) from the mode
hub (2).
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INPUT GEAR
1. Remove the input gear assembly (2) retaining ring
(1) from the transfer case.
2. Remove the input gear assembly (1) from the
transfer case front case.
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil
feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT AND SPROCKET INSPECTION
Inspect the splines on the shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an
oilstone. However, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed
with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND BEARING ASSEMBLY
Check the teeth on the input gear. Minor nicks can be dressed off with an oilstone but replace the gear if any teeth
are broken, cracked, or chipped. Check the bearing for smooth operation. Replace the input gear and bearing
assembly if the bearing exhibits any sign of damage or rough rotation.
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TRANSFER CASE - NV144 - SERVICE INFORMATION
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SHIFT FORK AND SLEEVE
Check condition of the shift fork and mode fork shift
rail. Minor nicks on the shift rail can be smoothed with
320-400 grit emery cloth.
Inspect the shift fork wear pads (1). The mode fork
pads
are
serviceable
and
can
be
replaced
if
necessary.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the 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. Replace the shaft if the splines 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.
FRONT/REAR CASES
Inspect the cases for wear and damage. Replace the input shaft 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.
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
1. Remove the front output shaft bearing retaining
ring from inside the front case (1) half.
2. Using Installer 6953 and Handle C-4171, remove
front output shaft bearing.
3. Start the front output shaft bearing in case. Then
seat bearing with Handle C-4171 (3) and Installer
6953 (2).
4. Install the front output shaft bearing retaining ring.
5. Remove the front output shaft rear bearing with the
screw and jaws from Remover L-4454 (2) and Cup
8148 (3).
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TRANSFER CASE - NV144 - SERVICE INFORMATION
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