Dodge Durango (DN). Manual — part 151

aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.

Examine the drive chain and shaft bearings.

Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.

LOW RANGE ANNULUS GEAR

Inspect annulus gear condition carefully. The gear

is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 92).

FRONT-REAR CASES AND FRONT RETAINER

Inspect the cases and retainer for wear and dam-

age. Clean the sealing surfaces with a scraper and all
purpose cleaner. This will ensure proper sealer adhe-
sion at assembly. Replace the input retainer seal; do
not reuse it.

Check case condition. If leaks were a problem, look

for gouges and severe scoring of case sealing sur-

faces. Also make sure the front case mounting studs
are in good condition.

Check the front case mounting studs and vent

tube. The tube can be secured with Loctite

y 271 or

680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoil stainless
steel inserts if required.

OIL PUMP/OIL PICKUP

Examine the oil pump pickup parts. Replace the

pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.

Fig. 91 Seal Contact Surface Of Yoke Slinger

1 – FRONT SLINGER (PART OF YOKE)
2 – SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH

Fig. 92 Low Range Annulus Gear

1 – FRONT CASE
2 – LOW RANGE ANNULUS GEAR

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NV242 TRANSFER CASE

DN

CLEANING AND INSPECTION (Continued)

ADJUSTMENTS

SHIFTER ADJUSTMENT

(1) Shift transfer case into the 4WD position.
(2) Raise vehicle.
(3) Loosen the trunnion lock bolt (Fig. 93).
(4) Make sure the shift rod slides freely in the

adjusting swivel. Lube rod and swivel if necessary.

(5) Verify that transfer case range lever is in 4WD

detent. The 4WD detent is the second detent position
from the full forward position.

(6) Align the adjustment locating hole in the lower

shift lever to the adjustment channel in the shifter
body (Fig. 94).

(7) Insert an appropriately sized pin through the

adjustment hole and channel.

(8) Tighten the trunnion lock bolt to 10 N·m (90

in. lbs.) torque.

(9) Lower vehicle just enough to enter vehicle. Be

sure all wheels are off shop floor. Then start engine,
shift transmission into gear, and shift transfer case
through all ranges to verify correct adjustment.

SPECIFICATIONS

TORQUE

DESCRIPTION

TORQUE

Plug, Detent . . . . . . . . . . 16–24 N·m (12–18 ft. lbs.)
Bolt, Diff. Case . . . . . . . . 17–27 N·m (15–24 ft. lbs.)
Plug, Drain/Fill . . . . . . . 20–25 N·m (15–25 ft. lbs.)
Bolt, Front Brg.

Retainer . . . . . . . . . . . 16–27 N·m (12–20 ft. lbs.)

Bolt, Case Half . . . . . . . . 35–46 N·m (26–34 ft. lbs.)
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. lbs.)
Screw, Oil Pump . . . . . 1.2–1.8 N·m (12–15 in. lbs.)
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. lbs.)
Bolt, Rear Retainer . . . . 20–27 N·m (15–20 ft. lbs.)
Nuts, Mounting . . . . . . . 30–41 N·m (20–30 ft. lbs.)
Bolts, U-Joint . . . . . . . . . . . . . . 19 N·m (17 ft. lbs.)
Nut, Shifter Knob . 11.3–13.6 N·m (100–120 in.lbs.)
Bolt, Shift Lever . . 22.6–33.9 N·m (200–300 in.lbs.)

Fig. 93 Transfer Case Shift Linkage

Fig. 94 Shifter Adjustment Channel and Hole

1 – LOCATING PIN
2 – ADJUSTMENT CHANNEL
3 – LOWER SHIFTER LEVER
4 – LOCATING HOLE

DN

NV242 TRANSFER CASE

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SPECIAL TOOLS

NV242

Handle, Universal—C-4171

Remover—C-4210

Installer, Bearing—5064

Installer—8128

Installer—5066

Installer—6952-A

Remover—L-4454

Cup—8148

Installer, Input Gear Bearing—7829-A

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NV242 TRANSFER CASE

DN

Installer, Seal—7884

Installer, Pump Housing Seal—7888

Installer, Bearing—8033-A

Remover, Bushing—6957

Installer, Bushing—8160

DN

NV242 TRANSFER CASE

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SPECIAL TOOLS (Continued)