Dodge Durango (HB). Manual — part 1364
6. Install the new front output shaft seal slinger (1)
with Installer 8840 (2). Install the slinger onto the
shaft until the tool contacts the front of the output
shaft.
7. Install the front sprocket (1), rear sprocket (3), and
chain (2) as an assembly.
8. Lower the front sprocket (1), rear sprocket (3), and
chain (2) over the front and rear output shafts
simultaneously until fully seated on both splines.
9. Install the rear output shaft retaining ring (2) onto
the output shaft (1).
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TRANSFER CASE - NV244 GENII - SERVICE INFORMATION
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10. Install the front sprocket retaining ring (2).
11. Inspect the mode fork assembly (1). Replace pads
if necessary. Also check springs (2) and slider
bracket. Replace worn or damaged components.
12. Install the mode fork (2) and sleeve (3) over the
shift rail (1) and mainshaft.
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TRANSFER CASE - NV244 GENII - SERVICE INFORMATION
HB
13. Install the shift rail spring (2) onto the shift rail (1).
14. Insert the transfer case sump magnet (1) into the
front case pocket (2).
OIL PUMP AND REAR CASE
Lubricate the oil pump components with transmission fluid before installation. Prime the oil pickup tube by pouring
a little oil into the tube before installation.
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft inner
bearing race and will become mis-aligned if the
bolts are loosened. If the transfer case failure has
generated any debris which may have become
trapped in the oil pump. the rear case and oil
pump assembly MUST be replaced.
1. Install a new o-ring in pickup tube inlet of oil pump,
if necessary.
2. Insert the oil pickup tube into the oil pump.
3. Apply bead of Mopar
T
Gasket Maker, or equivalent,
to mating surface of front case (2). Keep sealer
bead width to maximum of 3/16 inch. Do not use
excessive amount of sealer as excess will be dis-
placed into case interior.
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NOTE: Lift upward and gently shake the rear output shaft while settling the rear case onto the front case
dowels. This will allow the mainshaft splines to more easily engage the oil pump.
4. Align the oil pump with mainshaft and align shift rail with bore in rear case (1). Then install rear case (1) and oil
pump assembly.
5. Install the rear output bearing snap-ring (3) to the
rear output shaft (1).
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.
6. Install 4-5 rear case-to front case bolts (3) to hold
rear case in position. Tighten bolts snug but not to
specified torque at this time.
7. Apply Mopar
T
Lock ’n Seal Adhesive to remainder
of rear case-to-front case bolt threads and install
bolts. Tighten bolts to 25-28 N·m (18-21 ft. lbs.).
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TRANSFER CASE - NV244 GENII - SERVICE INFORMATION
HB
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