Dodge Durango (DN). Manual — part 139
(5) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 17).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case. The
case alignment bolts require flat washers (Fig. 18).
Fig. 18 Rear Case Alignment Bolt Locations
1 – ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 13 Oil Pump Removal
1 – OIL PUMP
Fig. 14 Pick-up Tube O-ring Location
1 – OIL PUMP
2 – O-RING
Fig. 15 Yoke Nut Removal
1 – IMPACT WRENCH
2 – SOCKET
3 – YOKE
Fig. 16 Yoke Removal
1 – PULLER TOOL
2 – YOKE
Fig. 17 Range Lever Removal
1 – RANGE LEVER
2 – SECTOR SHAFT
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NV231 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert pry tool blade only into
notches provided at each end of case (Fig. 19).
(4) Remove rear case from front case.
(5) Remove oil pickup tube from rear case (Fig.
20).
(6) Remove mode fork spring (Fig. 21).
(7) Pull front output shaft upward and out of front
output shaft bearing (Fig. 22).
(8) Remove front output shaft and chain.
Fig. 19 Loosening Rear Case
1 – REAR CASE
2 – PRY TOOL
(IN CASE SLOT)
3 – FRONT CASE
Fig. 20 Oil Pickup Tube Removal
1 – CONNECTING HOSE
2 – PICKUP SCREEN
3 – PICKUP TUBE
Fig. 21 Mode Fork Spring Removal
1 – MODE SPRING
Fig. 22 Remove Front Output Shaft And Chain
1 – DRIVE CHAIN
2 – FRONT OUTPUT SHAFT
3 – SHAFT FRONT BEARING
DN
NV231 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 23).
(2) Remove mainshaft from mode sleeve and input
gear pilot bearing.
(3) Remove mode fork and sleeve as an assembly
(Fig. 24). Note position of sleeve for assembly refer-
ence. The short side of the sleeve faces upward.
(4) Remove range fork and hub as an assembly
(Fig. 25). Note fork position for installation reference.
(5) Remove shift sector from front case (Fig. 26).
(6) Remove shift sector bushing and O-ring (Fig.
27).
Fig. 25 Range Fork And Hub Removal
1 – RANGE HUB
2 – RANGE FORK
Fig. 26 Shift Sector Removal
1 – SHIFT SECTOR
Fig. 27 Sector Bushing And O-Ring Removal
1 – SEAL RETAINER
2 – SECTOR SHAFT BORE
3 – O-RING SEAL
Fig. 23 Detent Plug, Spring And Plunger Removal
1 – PLUNGER
2 – O-RING
3 – PLUG
4 – SPRING
Fig. 24 Mode Fork And Sleeve Removal
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
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NV231 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
MAINSHAFT DISASSEMBLY
(1) Remove mode hub retaining ring with heavy
duty snap-ring pliers (Fig. 28).
(2) Slide mode hub off mainshaft (Fig. 29).
(3) Slide drive sprocket off mainshaft (Fig. 30).
INPUT GEAR AND LOW RANGE GEAR REMOVAL
(1) Remove front bearing retainer attaching bolts
(Fig. 31).
Fig. 31 Front Bearing Retainer Bolts
1 – FRONT CASE
2 – FRONT BEARING RETAINER
3 – RETAINER BOLTS
Fig. 28 Mode Hub Retaining Ring Removal
1 – MODE HUB
2 – SNAP RING PLIERS (HEAVY DUTY)
3 – MODE HUB RETAINING RING
Fig. 29 Mode Hub Removal
1 – MAINSHAFT
2 – MODE HUB
Fig. 30 Drive Sprocket Removal
1 – DRIVE SPROCKET
2 – MAINSHAFT
DN
NV231 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
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