Dodge Durango (DN). Manual — part 145

(7) Remove shifter knob.
(8) Remove the shifter bezel.
(9) Remove the shift lever.
(10) Remove bolts holding shifter to vehicle floor pan.
(11) Separate shifter from the vehicle.

INSTALLATION

(1) If a new shifter is not being installed, secure an

appropriately sized pin through the adjustment channel
and hole, located in the base of the shifter body.

(2) Position shifter on the vehicle floor pan.
(3) Install the bolts to hold the shifter to the floor

pan. Tighten the bolts to 12.4 N·m (110 in.lbs.).

(4) Install the shift lever to the shifter. Tighten the

shift lever bolt to 28.3 N·m (250 in.lbs.).

(5) Install the shifter bezel.
(6) Install shift knob on shift lever.
(7) Install nut to hold shifter knob to shift lever.
(8) Install shifter knob cap.
(9) Raise the vehicle.
(10) Install the shift rod to the trunnion, if necessary.
(11) Tighten trunnion lock bolt 10 N·m (90 in.lbs).
(12) Remove the locating pin from the adjustment

channel and hole in the base of the shifter.

(13) Lower vehicle.
(14) Verify transfer case operation.

FRONT OUTPUT SHAFT SEAL

REMOVAL

(1) Raise vehicle.
(2) Remove front propeller shaft. Refer to Group 3,

Differential and Driveline, for proper procedure.

(3) Remove front output shaft yoke.
(4) Remove seal from front case with pry tool (Fig.

6).

INSTALLATION

(1) Install new front output seal in front case with

Installer Tool 6952-A as follows:

(a) Place new seal on tool. Garter spring on seal

goes toward interior of case.

(b) Start seal in bore with light taps from ham-

mer (Fig. 7). Once seal is started, continue tapping
seal into bore until installer tool seats against case.

Fig. 5 Shifter

Fig. 6 Remove Front Output Shaft Seal

1 – OUTPUT SHAFT SEAL
2 – PRYBAR

Fig. 7 Front Output Seal Installation

1 – INSTALLER 6952–A
2 – TRANSFER CASE

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NV242 TRANSFER CASE

DN

REMOVAL AND INSTALLATION (Continued)

REAR RETAINER BUSHING AND SEAL

REMOVAL

(1) Raise vehicle.
(2) Remove rear propeller shaft. Refer to Group 3,

Differential and Driveline, for proper procedure.

(3) Using a suitable pry tool or slide-hammer

mounted screw, remove the rear retainer seal.

(4) Using Remover 6957, remove bushing from

rear retainer (Fig. 8).

INSTALLATION

(1) Clean fluid residue from sealing surface and

inspect for defects.

(2) Position replacement bushing in rear retainer

with fluid port in bushing aligned with slot in retainer.

(3) Using

Installer

8160,

drive

bushing

into

retainer until installer seats against case (Fig. 9).

(4) Using Installer C-3995-A, install seal in rear

retainer (Fig. 10).

(5) Install propeller shaft.
(6) Verify proper fluid level.
(7) Lower vehicle.

DISASSEMBLY AND ASSEMBLY

NV242 TRANSFER CASE

DISASSEMBLY

REAR RETAINER

(1) Remove extension housing bolts.
(2) Tap extension housing with plastic or rawhide

mallet to loosen sealer (Fig. 11).

Fig. 9 Rear Retainer Bushing Install

1 – REAR RETAINER BUSHING
2 – INSTALLER 8160

Fig. 8 Rear Retainer Bushing Removal

1 – REMOVER 6957
2 – REAR RETAINER BUSHING

Fig. 10 Install Rear Retainer Seal

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3995-A

Fig. 11 Remove Extension Housing

1 – EXTENSION HOUSING
2 – PLASTIC HAMMER
3 – REAR RETAINER

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NV242 TRANSFER CASE

21 - 447

REMOVAL AND INSTALLATION (Continued)

(3) Separate extension housing from rear retainer.
(4) Remove rear bearing snap-ring (Fig. 12).

(5) Remove bolts holding rear retainer to rear case

half.

(6) Loosen rear retainer with pry tool to break

sealer bead. Pry only against retainer boss as shown
(Fig. 13).

(7) Remove rear bearing O.D. retaining ring with

snap ring pliers. Then tilt pump and slide it off out-
put shaft (Fig. 14)

(8) Remove pickup tube O-ring from pump (Fig.

15) but do not disassemble pump; it is not a repair-
able part.

(9) Remove seal from oil pump with pry tool.

Fig. 12 Remove Rear Bearing Snap-ring

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

Fig. 13 Loosening Rear Retainer

1 – REAR RETAINER
2 – TAB (2)
3 – SCREWDRIVER
4 – TAB

Fig. 14 Oil Pump Removal

1 – OIL PUMP

Fig. 15 Pickup Tube O-Ring Location

1 – OIL PUMP
2 – O-RING

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NV242 TRANSFER CASE

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DISASSEMBLY AND ASSEMBLY (Continued)

(10) Remove bolts attaching rear case to front case

(Fig. 16). Note position of the two black finish bolts at
each end of the case. These bolts go through the case
dowels and require a washer under the bolt head.

(11) Remove rear case from front case (Fig. 17).

Insert screwdrivers into slots cast into each end of
case. Then pry upward to break sealer bead and
remove rear case.

CAUTION: Do not pry on the sealing surface of either
case half as the surfaces will become damaged.

(12) Remove oil pickup tube and screen from rear

case (Fig. 18).

YOKE AND RANGE LEVER

(1) Remove front yoke nut:

(a) Move range lever to 4L position.
(b) Remove nut with socket and impact wrench

(Fig. 19).

Fig. 17 Loosening/Removing Rear case

1 – MAINSHAFT
2 – SCREWDRIVER
3 – FRONT CASE
4 – SCREWDRIVER
5 – REAR CASE

Fig. 16 Spline And Dowel Bolt Locations

1 – DOWEL BOLT AND WASHER (2)
2 – CASE BOLT (5)
3 – SPLINE HEAD BOLT (1)

Fig. 18 Oil Pickup Screen, Hose And Tube Removal

1 – CONNECTING HOSE
2 – PICKUP SCREEN
3 – PICKUP TUBE

Fig. 19 Yoke Nut Removal

1 – IMPACT WRENCH
2 – SOCKET
3 – YOKE

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NV242 TRANSFER CASE

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DISASSEMBLY AND ASSEMBLY (Continued)