Dodge Ram Truck 1500-2500-3500. Manual — part 1881

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 (1) on the transfer

case (2).

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. Mount transfer case on a transmission jack.

2. Secure transfer case to jack with chains.

3. Position transfer case under vehicle.

4. Align transfer case and transmission shafts and install transfer case onto the transmission.

5. Install and tighten transfer case attaching nuts to 27-34 N·m (20-25 ft. lbs.) torque.

6. Connect the vent hose.

7. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.

8. Align and connect the propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/FRONT

PROPELLER SHAFT - INSTALLATION) (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/REAR
PROPELLER SHAFT - INSTALLATION)

9. Fill transfer case with correct fluid. (Refer to 21 - TRANSMISSION/TRANSFER CASE/FLUID - STANDARD PRO-

CEDURE)

10. Install skid plate, if equipped.

11. Remove transmission jack and support stand.

12. Lower vehicle and verify transfer case shift operation.

SPECIFICATIONS

TRANSFER CASE - NV243

TORQUE SPECIFICATIONS

DESCRIPTION

N-m

Ft. Lbs.

In. Lbs.

Plug, Detent

16-24

12-18

-

Plug, Drain/Fill

20-34

15-25

-

Bolt, Extension Housing

16-24

12-18

-

Bolt, Case Half

20-27

15-24

-

Screw, Oil Pump

12-16

8-12

-

Nuts, Mounting

30-41

20-30

-

Bolts, Shift Motor and

Mode Sensor Assembly

16-24

12-18

-

21 - 1456

TRANSFER CASE - NV243 - SERVICE INFORMATION

DR/DH

SPECIAL TOOLS

TRANSFER CASE - NV243

Handle - C-4171

Installer, Seal - D-163

Tool Set - L-4518

Installer, Seal - MB991168A

Installer, Bushing - 5066

Installer, Bearing - 6953

Cup - 8148

Installer, Bearing - 8684

DR/DH

TRANSFER CASE - NV243 - SERVICE INFORMATION

21 - 1457

Installer - 8840

Installer, Seal - 8841

21 - 1458

TRANSFER CASE - NV243 - SERVICE INFORMATION

DR/DH

SEAL-EXTENSION HOUSING

REMOVAL

1. Raise and support vehicle.

2. Remove rear propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER

SHAFT - REMOVAL)

3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal.

INSTALLATION

1. Clean fluid residue from sealing surface and

inspect for defects.

2. Using Installer D-163 (2) and Handle C-4171 (1),

install seal in extension housing.

3. Install propeller shaft. (Refer to 3 - DIFFERENTIAL

& DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)

4. Verify proper transfer case fluid level.

5. Lower vehicle.

FLUID

STANDARD PROCEDURE - FLUID DRAIN AND REFILL

The fill (2) and drain (3) plugs are both in the rear
case.

1. Raise vehicle.

2. Position drain pan under transfer case.

NOTE: It may be necessary to remove the exhaust
y-pipe at the exhaust manifold to properly access
the fill and drain plugs. Lowering the exhaust will
allow the plugs to be accessed for torquing during
installation. (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL)

3. Remove drain and fill plugs and drain lubricant

completely.

4. Install drain plug. Tighten plug to 20-34 N·m (15-25

ft. lbs.).

5. Remove drain pan.

6. Fill transfer case to bottom edge of fill plug opening with Mopar

T

ATF +4, Automatic Transmission fluid.

7. Install and tighten fill plug to 20-34 N·m (15-25 ft. lbs.).

8. Install the exhaust y-pipe to the exhaust manifold, if removed. (Refer to 11 - EXHAUST SYSTEM/EXHAUST

PIPE - INSTALLATION)

9. Wipe any excess fluid that may have spilled onto the exhaust.

10. Lower vehicle.

DR/DH

TRANSFER CASE - NV243 - SERVICE INFORMATION

21 - 1459