Dodge Durango (DN). Manual — part 144

Installer, Bearing—8128

Remover—L-4454

Cup—8148

Installer, Seal—7884

Installer, Pump Housing Seal—7888

Holder, Yoke—C-3281

21 - 442

NV231 TRANSFER CASE

DN

SPECIAL TOOLS (Continued)

NV242 TRANSFER CASE

TABLE OF CONTENTS

page

page

DESCRIPTION AND OPERATION

NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 443
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 444

DIAGNOSIS AND TESTING

NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 444

REMOVAL AND INSTALLATION

TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 445
TRANSFER CASE SHIFTER. . . . . . . . . . . . . . . . 445
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 446
REAR RETAINER BUSHING AND SEAL . . . . . . . 447

DISASSEMBLY AND ASSEMBLY

NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 447

CLEANING AND INSPECTION

NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 468

ADJUSTMENTS

SHIFTER ADJUSTMENT. . . . . . . . . . . . . . . . . . . 471

SPECIFICATIONS

TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471

SPECIAL TOOLS

NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472

DESCRIPTION AND OPERATION

NV242 TRANSFER CASE

DESCRIPTION

The NV242 is a full and part-time transfer case

(Fig. 1) with no two wheel drive operation.

A differential in the transfer case is used to control

torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.

The input gear is splined to the transmission out-

put shaft. It drives the mainshaft through the plan-
etary gear and range hub. The front output shaft is
operated by a drive chain that connects the shaft to a

drive sprocket on the mainshaft. The drive sprocket
is engaged/disengaged by the mode fork, which oper-
ates the mode sleeve and hub. The sleeve and hub
are not equipped with a synchro mechanism for shift-
ing.

The geartrain is mounted in two aluminum case

halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.

TRANSFER CASE IDENTIFICATION

A circular ID tag is attached to the rear case of

each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.

The transfer case serial number also represents

the date of build.

Fig. 1 NV242 Transfer Case

Fig. 2 Fill/Drain Plug And I.D. Tag Locations

1 – I.D. TAG
2 – FILL PLUG
3 – DRAIN PLUG

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NV242 TRANSFER CASE

21 - 443

OPERATING RANGES

NV242 operating ranges are 4HI LOCK (part-

time), 4HI LOCK (full time), and 4LO LOCK.

The 4WD modes can be used at any time and on

any road surface.

The 4HI LOCK (part-time) and 4LO LOCK ranges

are for off road use only. The only time these ranges
can be used on hard surface roads, is when the sur-
face is covered with snow and ice.

SHIFT MECHANISM

Operating

ranges

are

selected

with

a

body

mounted shift lever. The shift lever is connected to
the transfer case range lever by an adjustable link-
age rod. A straight line shift pattern is used. Range
positions are marked on the shifter bezel cover plate,
or on the shift knob.

LUBRICANT AND FILL LEVEL

DESCRIPTION

Recommended lubricant for the NV242 transfer

case is Mopar

t Dexron III, or ATF+3, type 7176.

Approximate lubricant fill capacity is 1.35 liters (2.85
pints).

The fill and drain plugs are both in the rear case

(Fig. 3). Correct fill level is to the bottom edge of the

fill plug hole. Be sure the vehicle is level to ensure
an accurate fluid level check.

DIAGNOSIS AND TESTING

NV242 DIAGNOSIS

DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSE

CORRECTION

Transfer case difficult to shift or will
not shift into desired range.

1) Transfer case shift linkage
binding.

1) Repair or replace linkage as
necessary.

2) Insufficient or incorrect lubricant.

2) Drain and refill transfer case with
the correct quantity of Mopar

T

DexronIII or ATF+3, type 7176,
Automatic transmission fluid.

3) Internal transfer case
components binding, worn, or
damaged.

3) Repair or replace components as
necessary.

Transfer case noisy in all drive
modes.

1) Insufficient or incorrect lubricant.

1) Drain and refill transfer case with
the correct quantity of Mopar

T

DexronIII or ATF+3, type 7176,
Automatic transmission fluid.

Lubricant leaking from transfer case
seals or vent.

1) Transfer case overfilled.

1) Drain lubricant to the correct
level.

2) Transfer case vent closed or
restricted.

2) Clean or replace vent as
necessary.

3) Transfer case seals damaged or
installed incorrectly.

3) Replace suspect seal.

Fig. 3 Fill/Drain Plug Locations

1 – I.D. TAG
2 – FILL PLUG
3 – DRAIN PLUG

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NV242 TRANSFER CASE

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DESCRIPTION AND OPERATION (Continued)

CONDITION

POSSIBLE CAUSE

CORRECTION

Transfer case will not shift through
4HI LOCK (part time) range (light
remains on)

1) Incomplete shift due to drivetrain
torque load.

1) Momentarily release the
accelerator pedal to complete the
shift.

2) Incorrect tire pressure.

2) Correct tire pressure as
necessary.

3) Excessive Tire wear.

3) Correct tire condition as
necessary.

4) Excessive vehicle loading.

4) Correct as necessary.

REMOVAL AND INSTALLATION

TRANSFER CASE

REMOVAL

(1) Shift transfer case into 4WD.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shafts for align-

ment reference.

(5) Support transmission with jack stand.
(6) Remove skid plate, if equipped.
(7) Disconnect front and rear propeller shafts at

transfer case.

(8) Disconnect transfer case linkage rod from

range lever.

(9) Disconnect transfer case vent hose (Fig. 4) and

indicator switch harness, if necessary.

(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-

mission.

(13) Pull transfer case and jack rearward to disen-

gage transfer case.

(14) Remove transfer case from under vehicle.

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 on transmission.

(5) Install and tighten transfer case attaching nuts

to 35 N·m (26 ft. lbs.) torque (Fig. 4).

(6) Connect vent hose.
(7) Connect indicator switch harness to transfer

case switch, if necessary. Secure wire harness to clips
on transfer case.

(8) Align and connect the propeller shafts.
(9) Fill transfer case with correct fluid. Refer to

Lubricant And Fill Level section for proper fluid and
capacity.

(10) Install rear crossmember and skid plate, if

equipped. Tighten crossmember bolts to 41 N·m (30
ft. lbs.) torque.

(11) Remove transmission jack and support stand.
(12) Connect shift rod to transfer case range lever.
(13) Verify the adjustment of the transfer case

shift linkage.

(14) Lower vehicle and verify transfer case shift

operation.

TRANSFER CASE SHIFTER

REMOVAL

(1) Shift transfer case and shifter into the 42WD

position.

(2) Raise and support vehicle.
(3) Loosen adjusting trunnion lock bolt and slide

shift rod out of trunnion (Fig. 5). If rod lacks enough
travel to come out of trunnion, push trunnion out of
the shifter arm.

(4) Lower the vehicle.
(5) Remove transfer case shifter knob cap.
(6) Remove nut holding shifter knob to shift lever.

Fig. 4 Transfer Case Mounting–Typical

1 – MOUNTING STUDS
2 – TRANSFER CASE
3 – TRANSMISSION

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NV242 TRANSFER CASE

21 - 445

DIAGNOSIS AND TESTING (Continued)