Dodge Ram Truck 1500-2500-3500. Manual — part 1857
2. Install the front output shaft retaining ring (2) onto
the output shaft.
3. Install the new front output shaft seal with Installer
MB991168A.
4. Insert front sprocket in drive chain.
5. Install drive chain (2) around mainshaft sprocket
(1). Then position front sprocket over front shaft.
6. Raise mainshaft about 2.54 cm (one inch) and seat
front sprocket on front output shaft.
7. If mainshaft and mode sleeve were unseated dur-
ing chain installation, align and reseat mainshaft in
input gear and hub.
8. Install front sprocket (1) retaining ring (2).
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TRANSFER CASE - NV241 GENII - SERVICE INFORMATION
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9. Install spring (2) and cup (1) on shift rail.
10. Insert magnet (1) in front case pocket (2).
OIL PUMP AND REAR CASE
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. Apply bead of Mopar
T
Gasket Maker, or equivalent,
to mating surface of front case. Keep sealer bead
width to maximum of 3/16 inch. Do not use exces-
sive amount of sealer as excess will be displaced
into case interior.
2. Align oil pump with mainshaft and align shift rail
with bore in rear case. Then install rear case (1)
and oil pump assembly.
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3. Install 4-5 rear case(1)-to front case (2) bolts to
hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
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.
4. Apply Loctite™ 242 to remainder of rear case-to-
front case bolt threads and install bolts. Tighten
bolts to 20-27 N·m (15-24 ft. lbs.),
5. Install rear output bearing (2) snap-ring (3) to out-
put shaft.
SEAL BOOT
1. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts
the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.
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TRANSFER CASE - NV241 GENII - SERVICE INFORMATION
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REAR EXTENSION
1. Install new seal in rear extension housing seal with
Installer D-163 and Handle C-4171..
2. Apply bead of Mopar
T
Gasket Maker, or equivalent,
to mating surface of rear extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could
be displaced into output bearing.
3. Align and install rear extension housing (1) on
retainer.
4. Apply Mopar
T
Silicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N·m (12-18 ft. lbs.) torque.
INSTALLATION
1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with trans-
mission output shaft. Align splines by rotating transfer case rear output shaft yoke if necessary. Do not install any
transfer case attaching nuts until the transfer case is completely seated against the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41 N·m (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER SHAFT - INSTALLATION)
5. Connect vent hose and transfer case position sensor connector.
6. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into
lever grommet.
7. Adjust shift linkage, if necessary.
8. Fill transfer case with recommended transmission fluid and install fill plug.
9. Install skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE -
INSTALLATION)
10. Lower vehicle
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