Dodge Durango (DN). Manual — part 138

Condition

Possible Cause

Correction

Transfer case noisy while in, or
jumps out of, 4LO LOCK mode.

1) Transfer case not completely
engaged in 4LO LOCK position.

1) With the transmission in neutral,
or clutch depressed on vehicles
equiped with a manual transmission,
shift transfer case to the Neutral
position, and then back into the 4LO
LOCK position.

2) Transfer case shift linkage out of
adjustment.

2) Adjust linkage as necessary.

3) Transfer case shift linkage loose
or binding.

3) Repair, replace, or tighten linkage
components as necessary.

4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.

4) Repair or replace components as
necessary.

5) Low range gear worn or
damaged.

5) Repair or replace components as
necessary.

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.

Abnormal tire wear.

1) Extended operation in 4HI
LOCKmode on dry surfaces,

1) Operate vehicle in 2H mode on
dry surfaces.

REMOVAL AND INSTALLATION

TRANSFER CASE

REMOVAL

(1) Shift transfer case into 2WD.
(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 rear crossmember and 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. 3) 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.

Fig. 3 Transfer Case Mounting–Typical

1 – MOUNTING STUDS
2 – TRANSFER CASE
3 – TRANSMISSION

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NV231 TRANSFER CASE

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DIAGNOSIS AND TESTING (Continued)

(5) Install and tighten transfer case attaching nuts

to 35 N·m (26 ft. lbs.) torque (Fig. 3).

(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 2WD

position.

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

shift rod out of trunnion (Fig. 4). 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.
(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 neces-

sary.

(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.

5).

INSTALLATION

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

Installer Tool 8143 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. 6). Once seal is started, continue tapping
seal into bore until installer tool seats against case.

REAR RETAINER BUSHING AND SEAL

REMOVAL

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

Differential and Driveline, for proper procedure.

Fig. 4 Shifter

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NV231 TRANSFER CASE

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REMOVAL AND INSTALLATION (Continued)

(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. 7).

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. 8).

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

retainer (Fig. 9).

(5) Install propeller shaft.

(6) Verify proper fluid level.
(7) Lower vehicle.

DISASSEMBLY AND ASSEMBLY

NV231 TRANSFER CASE

DISASSEMBLY

Position transfer case on shallow drain pan.

Remove drain plug and drain lubricant remaining in
case.

REAR RETAINER AND OIL PUMP REMOVAL

(1) Remove extension housing bolts.

Fig. 5 Remove Front Output Shaft Seal

1 – OUTPUT SHAFT SEAL
2 – PRYBAR

Fig. 6 Front Output Seal Installation

1 – INSTALLER 8143
2 – TRANSFER CASE

Fig. 7 Rear Retainer Bushing Removal

1 – REMOVER 6957
2 – REAR RETAINER BUSHING

Fig. 8 Rear Retainer Bushing Install

1 – REAR RETAINER BUSHING
2 – INSTALLER 8160

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REMOVAL AND INSTALLATION (Continued)

(2) Tap extension housing with plastic or rawhide

mallet to loosen sealer (Fig. 10).

(3) Separate extension housing from rear retainer.
(4) Remove rear bearing snap-ring (Fig. 11).
(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. 12).

(7) Disengage oil pickup tube from oil pump and

remove oil pump assembly (Fig. 13).

(8) Remove pick-up tube o-ring from oil pump (Fig.

14), if necessary. Do not disassemble the oil pump, it
is not serviceable.

YOKE AND RANGE LEVER REMOVAL

(1) Remove transfer case indicator switch.
(2) Remove front yoke nut as follows:

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

wrench (Fig. 15).
(3) Remove yoke. If yoke is difficult to remove by

hand, remove it with bearing splitter, or with stan-
dard two jaw puller (Fig. 16). Be sure puller tool is
positioned on yoke and not on slinger as slinger will
be damaged.

(4) Remove seal washer from front output shaft.

Discard washer as it should not be reused.

Fig. 9 Install Rear Retainer Seal

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

Fig. 10 Remove Extension Housing

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

Fig. 11 Remove Rear Bearing Snap-ring

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

Fig. 12 Loosening Rear Retainer

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

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NV231 TRANSFER CASE

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DISASSEMBLY AND ASSEMBLY (Continued)