Dodge Durango (DN). Manual — part 143

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. 79). 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.

SHIFT FORKS/HUBS/SLEEVES

Check condition of the shift forks and mode fork

shift rail (Fig. 80). Minor nicks on the shift rail can
be smoothed with 320–400 grit emery cloth.

Inspect the shift fork wear pads (Fig. 81). The

mode fork pads are serviceable and can be replaced if
necessary. The range fork pads are not serviceable.
The fork must be replaced as an assembly if the pads
are worn or damaged.

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 3M all purpose cleaner.

Fig. 79 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. 80 Shift forks

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

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CLEANING AND INSPECTION (Continued)

This will ensure proper adhesion of the sealer during
reassembly.

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. 82). 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-
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. 83)

FRONT-REAR CASES AND FRONT RETAINER

Inspect the cases and retainer for wear and dam-

age. Clean the sealing surfaces with a scraper and
3M all purpose cleaner. This will ensure proper
sealer adhesion 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 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

Fig. 81 Shift Fork And Wear Pad Locations

1 – RANGE FORK
2 – MODE FORK
3 – WEAR PADS (SERVICEABLE)
4 – WEAR PADS (NON-SERVICEABLE)

Fig. 82 Seal Contact Surface Of Yoke Slinger

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

Fig. 83 Low Range Annulus Gear

1 – FRONT CASE
2 – LOW RANGE ANNULUS GEAR

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NV231 TRANSFER CASE

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CLEANING AND INSPECTION (Continued)

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.

ADJUSTMENTS

SHIFTER ADJUSTMENT

(1) Shift transfer case into the 2WD position.
(2) Raise vehicle.
(3) Loosen the trunnion lock bolt (Fig. 84).
(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 2WD

detent. The 2WD 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. 85).

(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.)
Plug, Drain/Fill . . . . . . . 20–34 N·m (15–25 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Case Half . . . . . . . . 27–34 N·m (20–25 ft. lbs.)
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. lbs.)
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. lbs.)
Bolt, Rear Retainer . . . . 35–46 N·m (26–34 ft. lbs.)
Nuts, Mounting . . . . . . . 30–41 N·m (20–30 ft. lbs.)
Switch, Indicator . . . . . . 20–34 N·m (15–25 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. 84 Transfer Case Shift Linkage

Fig. 85 Shifter Adjustment Channel and Hole

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

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CLEANING AND INSPECTION (Continued)

SPECIAL TOOLS

NV231

Installer, Seal—8143

Remover, Bushing—6957

Installer, Bushing—8160

Installer, Seal—C-3995-A

Handle, Universal—C-4171

Installer, Seal—C-4210

Installer, Bearing—5064

Installer, Bearing—5065

Installer, Bushing—5066

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