Dodge Durango (DN). Manual — part 150

(3) Install drive sprocket (Fig. 83). Engage drive

sprocket teeth with chain. Then engage sprocket
splines with mainshaft splines.

(4) Install drive sprocket snap-ring (Fig. 84).

OIL PUMP AND REAR CASE

(1) Insert oil pickup tube in oil pump and attach

oil screen and connector hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 85). Be sure screen is seated in case slot as
shown.

Fig. 79 Assembled Mainshaft And Mode Fork

Installation

1 – MAINSHAFT ASSEMBLY
2 – MODE FORK

Fig. 80 Shift Rail Installation

1 – SHIFT RAIL
2 – MODE FORK

Fig. 81 Installing Low Range Fork Lockpin

1 – LOW RANGE FORK LOCK PIN
2 – ACCESS HOLE
3 – EASY-OUT

Fig. 82 Detent Pin, Spring And Plug Installation

1 – PLUNGER
2 – O-RING
3 – PLUG
4 – SPRING

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DISASSEMBLY AND ASSEMBLY (Continued)

(2) Install magnet in front case pocket (Fig. 86).
(3) Apply 3 mm (1/8 in.) wide bead of Mopar gas-

ket maker or silicone adhesive sealer to seal surface
of front case.

(4) Align and install rear case on front case. Be

sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.

(5) Install and tighten front case-to-rear case bolts

to 41 N·m (30 ft. lbs.) torque. Be sure to install a
washer under each bolt used at case dowel
locations.

Fig. 83 Drive Chain And Sprocket Installation

1 – FRONT OUTPUT SHAFT
2 – DRIVE CHAIN
3 – DRIVE SPROCKET

Fig. 84 Drive Sprocket Snap-Ring Installation

1 – DRIVE SPROCKET
2 – DRIVE SPROCKET SNAP RING

Fig. 85 Oil Screen And Pickup Tube Installation

1 – OIL PUMP
2 – OIL SCREEN
3 – CONNECTOR
4 – PICKUP TUBE

Fig. 86 Installing Case Magnet

1 – MAGNET

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NV242 TRANSFER CASE

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DISASSEMBLY AND ASSEMBLY (Continued)

REAR RETAINER

(1) Install rear bearing O.D. retaining ring with

snap-ring pliers (Fig. 87). Be sure retaining ring is
fully seated in retainer groove.

(2) Apply bead of Mopar

t Sealer P/N 82300234, or

Loctite

y Ultra Gray, to mating surface of rear

retainer. Sealer bead should be a maximum of 3/16
in.

(3) Install rear retainer on rear case. Tighten

retainer bolts to 20–27 N·m (15–20 ft. lbs.) torque.

(4) Install new output shaft bearing snap-ring

(Fig. 88). Lift mainshaft slightly to seat snap-ring in
shaft groove, if necessary.

(5) Apply 3 mm (1/8 in.) wide bead of Mopar

t gas-

ket maker or silicone adhesive sealer to mounting
surface of extension housing. Allow sealer to set-up
slightly before proceeding.

(6) Install extension housing on rear retainer.
(7) Install extension housing bolts and tighten to

35–46 N·m (26–34 ft. lbs.).

FRONT YOKE AND SWITCH

(1) Install indicator switch in front case. Tighten

switch to 20–34 N·m (15–25 ft. lbs.) torque.

(2) Lubricate yoke hub with transmission fluid and

install yoke on front shaft.

(3) Install new seal washer on front shaft.
(4) Install yoke on front shaft. Secure yoke with

new nut.

CLEANING AND INSPECTION

NV242 TRANSFER CASE

Clean the transfer case parts with a standard

parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and all
purpose cleaner. Use compressed air to remove sol-
vent residue from oil feed passages in the case
halves, retainers, gears, and shafts.

The oil pickup screen can be cleaned with solvent.

Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.

MAINSHAFT/SPROCKET/HUB INSPECTION

Inspect the splines on the hub and shaft and the

teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part is damaged.

Check the contact surfaces in the sprocket bore

and on the mainshaft. Minor nicks and scratches can
be smoothed with 320–400 grit emery cloth but do
not try to salvage the shaft if nicks or wear is severe.

INPUT GEAR AND PLANETARY CARRIER

Check the teeth on the gear (Fig. 89). Minor nicks

can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300–400 grit emery cloth if necessary.

Examine the carrier body and pinion gears for

wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.

Check the lock ring and both thrust washers for

wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.

Fig. 87 Rear Bearing Retaining Ring Installation

1 – REAR BEARING O.D. RETAINING RING
2 – SNAP RING PLIERS

Fig. 88 Install Output Bearing Snap-ring

1 – REAR RETAINER
2 – SNAP RING
3 – REAR BEARING

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DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT FORKS/HUBS/SLEEVES

Check condition of the shift forks and mode fork

shift rail (Fig. 90). Minor nicks on the shift rail can
be smoothed with 320–400 grit emery cloth.

Inspect the shift fork wear pads. The mode fork

pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.

Check both of the sleeves for wear or damage,

especially on the interior teeth. Replace the sleeves if
wear or damage is evident.

REAR RETAINER AND EXTENSION HOUSING

Inspect the retainer components. Replace the bear-

ing if rough or noisy. Check the retainer for cracks or
wear in the bearing bore. Clean the retainer sealing
surfaces with a scraper and all purpose cleaner. This
will ensure proper adhesion of the sealer during reas-
sembly.

Inspect the retaining rings and washers. Replace

any part if distorted, bent, or broken. Reuse is not
recommended.

Inspect the extension housing seal and bushing.

Replace both components if either shaoe any sign of
wear or damage.

FRONT OUTPUT SHAFT/YOKE/DRIVE CHAIN

Check condition of the seal contact surfaces of the

yoke slinger (Fig. 91). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut and seal washer as neither part should be
reused.

Inspect the shaft threads, sprocket teeth, and bear-

ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320–400 grit emery
to smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-

Fig. 89 Input Gear And Carrier Components

1 – PLANETARY CARRIER
2 – REAR THRUST WASHER
3 – FRONT THRUST WASHER

4 – CARRIER LOCK RING
5 – CARRIER LOCK RETAINING RING
6 – INPUT GEAR

Fig. 90 Shift forks

1 – RANGE FORK
2 – MODE FORK AND RAIL
3 – MODE SPRING

DN

NV242 TRANSFER CASE

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CLEANING AND INSPECTION (Continued)