Dodge Durango (DN). Manual — part 147
(14) Remove low range fork and hub (Fig. 35).
(15) Remove shift sector (Fig. 36).
(16) Remove shift sector bushing and O-ring (Fig.
37).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Remove front bearing retainer bolts.
(2) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 38). Position
screwdriver in slots cast into retainer.
Fig. 38 Front Bearing Retainer Removal
1 – FRONT BEARING RETAINER
2 – RETAINER SLOT
Fig. 35 Low Range Fork And Hub Removal
1 – LOW RANGE FORK
2 – FORK HUB
Fig. 36 Shift Sector Position
1 – SHIFT SECTOR
2 – LOW RANGE FORK
3 – PIN
4 – SLOT
Fig. 37 Sector Bushing And O-Ring Removal
1 – SHIFT SECTOR BUSHING
2 – O-RING
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove input gear snap-ring (Fig. 39).
(4) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 40).
(5) Remove low range gear snap-ring (Fig. 41).
(6) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 42).
Fig. 39 Input Gear Snap-Ring Removal
1 – INPUT GEAR
2 – SNAP RING
Fig. 40 Input And Low Range Gear Assembly
Removal
1 – INPUT-LOW RANGE GEARS
2 – SPECIAL TOOL 7829A
3 – SPECIAL TOOL C-4171
Fig. 41 Low Range Gear Snap-Ring Removal/
Installation
1 – LOW RANGE GEAR SNAP RING
Fig. 42 Low Range Gear Disassembly
1 – THRUST WASHERS
2 – LOW RANGE GEAR
3 – INPUT GEAR
4 – RETAINER
DN
NV242 TRANSFER CASE
21 - 455
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Inspect low range annulus gear (Fig. 43). Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oil seals from following components:
• front bearing retainer.
• rear retainer.
• oil pump.
• case halves.
DIFFERENTIAL
(1) Mark differential case halves for reference.
(2) Remove differential case bolts.
(3) Invert differential on workbench.
(4) Separate top case from bottom case. Use slots
in case halves to pry them apart (Fig. 44).
(5) Remove thrust washers and planet gears from
case pins (Fig. 45).
(6) Remove mainshaft and sprocket gears from
bottom case (Fig. 46). Note gear position for reference
before separating them.
ASSEMBLY
Lubricate transfer case components with automatic
transmission fluid or petroleum jelly (where indi-
cated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARING AND SEAL
(1) Remove snap-ring that retains front output
shaft front bearing in case (Fig. 47). Then remove
Fig. 43 Inspecting Low Range Annulus Gear
1 – LOW RANGE ANNULUS GEAR
Fig. 44 Separating Differential Case Halves
1 – TOP CASE
2 – CASE BOLTS
3 – CASE BOLTS
4 – CASE SLOTS
5 – CASE BOLTS
Fig. 45 Planet Gears And Thrust Washer Removal
1 – BOTTOM CASE
2 – THRUST WASHERS (12)
3 – PLANET GEARS (6)
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
bearing. Use hammer handle, or hammer and brass
punch to tap bearing out of case.
(2) Install new front output shaft front bearing
with Tool Handle C-4171 and Installer 8033A with
the tapered cone upward (Fig. 48).
(3) Install front bearing snap-ring (Fig. 47).
(4) Remove front output shaft seal using an appro-
priate pry tool (Fig. 49) or slide-hammer mounted
screw.
(5) Install new front output shaft oil seal with
Installer 6952-A (Fig. 50).
Fig. 46 Mainshaft And Sprocket Gear Removal
1 – MAINSHAFT GEAR
2 – SPROCKET GEAR
3 – BOTTOM CASE
Fig. 47 Front Output Shaft Front Bearing Snap-Ring
Removal
1 – FRONT BEARING SNAP RING
Fig. 48 Front Output Shaft Front Bearing Installation
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 8033A
Fig. 49 Remove Front Output Shaft Seal
1 – OUTPUT SHAFT SEAL
2 – PRYBAR
DN
NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
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