Dodge Ram Truck 1500-2500-3500. Manual — part 1874
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 alignment
reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at trans-
fer case.
8. Disconnect transfer case shift motor and mode
sensor wire connectors (3).
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 (2) to transmission (1).
13. Pull transfer case and jack rearward to disengage 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 lubricant remaining in
case.
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TRANSFER CASE - NV243 - SERVICE INFORMATION
DR/DH
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL
1. Remove the bolts (3) which hold the shift motor
and mode sensor assembly (2) to the transfer case
(1).
2. Remove the shift motor and mode sensor assem-
bly from the transfer case.
3. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
4. Remove the front propeller shaft seal boot (1).
DR/DH
TRANSFER CASE - NV243 - SERVICE INFORMATION
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5. Remove the front output shaft seal slinger (1) by
bending (2) the slinger ears away from the transfer
case.
6. Using a suitable pry tool (2), remove the slinger (1)
from the output shaft using care not to damage the
shaft.
7. Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
1. Remove rear extension bolts (1).
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DR/DH
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.
3. Remove output bearing (2) retaining ring (3) with
heavy duty snap-ring pliers.
OIL PUMP AND REAR CASE
1. Remove rear case (1)-to-front case (2) bolts (3).
DR/DH
TRANSFER CASE - NV243 - SERVICE INFORMATION
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