Dodge Dakota (R1). Manual — part 737
REAR RETAINER
(1) Install rear bearing O.D. retaining ring with
snap-ring pliers (Fig. 78). Be sure retaining ring is
fully seated in retainer groove.
(2) Apply bead of Mopar® Sealer, or Loctite™
Ultra Gray, to mating surface of rear retainer. Sealer
bead should be a maximum of 3/16 in.
(3) Install rear retainer on rear case. Tighten
retainer bolts to 27-34 N·m (20-25 ft. lbs.) torque.
(4) Install new output shaft bearing snap-ring
(Fig. 79). Lift mainshaft slightly to seat snap-ring in
shaft groove, if necessary.
(5) Apply 3 mm (1/8 in.) wide bead of Mopar® Gas-
ket Maker, or equivalent silicone adhesive sealer, to
mounting surface of extension housing. Allow sealer
to set-up slightly before proceeding.
(6) Install extension housing on rear retainer.
(7) Install extension housing bolts and tighten to
27-34 N·m (20-25 ft. lbs.).
COMPANION FLANGE AND SHIFT MOTOR AND
MODE SENSOR ASSEMBLY
(1) Position the shift motor and mode sensor
assembly onto the transfer case.
(2) Install the bolts (Fig. 80) to hold the shift
motor and mode sensor assembly to the transfer
case. Tighten the bolts to 16-24 N·m (12-18 ft. lbs.)
torque.
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
Mopar® Lock & Seal or Loctite™ 242 to replenish
the lock patch material originally found on the bolts
Fig. 78 Rear Bearing Retaining Ring Installation
1 - REAR BEARING O.D. RETAINING RING
2 - SNAP-RING PLIERS
Fig. 79 Install Output Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 80 Install the Shift Motor and Mode Sensor
Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
21 - 592
TRANSFER CASE - NV244
AN
TRANSFER CASE - NV244 (Continued)
(3) Install new seal washer onto the front output
shaft (Fig. 81).
(4) Lubricate
the
companion
flange
hub
with
transmission fluid and install the flange onto the
front output shaft.
(5) Install a new companion flange nut onto the
front output shaft.
(6) Tighten the flange nut to 122-176 N·m (90-130
ft. lbs.) torque. Use Tool 6958, or similar tool to hold
flange while tightening nut.
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 onto the transmission.
(5) Install and tighten transfer case attaching nuts
to 27-34 N·m (20-25 ft. lbs.) torque.
(6) Connect the vent hose.
(7) Connect the shift motor and mode sensor wir-
ing connectors. Secure wire harness to clips on trans-
fer case.
(8) Align and connect the propeller shafts.
(9) Fill transfer case with correct fluid. (Refer to
21
-
TRANSMISSION/TRANSAXLE/TRANSFER
CASE/FLUID - STANDARD PROCEDURE)
(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) Lower vehicle and verify transfer case shift
operation.
SPECIFICATIONS
SPECIFICATIONS - TRANSFER CASE - NV244
TORQUE SPECIFICATIONS
DESCRIPTION
N-m
Ft. Lbs.
In. Lbs.
Plug, Detent
16-24
12-18
-
Bolt, Differential Case
17-27
15-24
-
Plug, Drain/Fill
20-34
15-25
-
Bolt, Front Brg. Retainer
16-25
12-18
-
Bolt, Case Half
27-34
20-25
-
Nut, Companion Flange
122-176
90-130
-
Bolt, Shift Motor and
Mode Sensor Assembly
16-25
12-18
-
Bolt, Rear Retainer
27-34
20-25
-
Bolt, Extension Housing
27-34
20-25
-
Nut, Mounting
27-34
20-25
-
Fig. 81 Yoke Seal Washer Installation
1 - YOKE SEAL WASHER
AN
TRANSFER CASE - NV244
21 - 593
TRANSFER CASE - NV244 (Continued)
SPECIAL TOOLS
TRANSFER CASE - NV244
Handle, Universal - C-4171
Remover, Bearing - C-4210
Installer, Bearing - 5064
Installer, Bearing - 8128
Installer, Bearing - 5066
Installer, Bearing - 5066
Installer, Seal - 6952-A
Remover, Bearing - L-4454
Cup - 8148
21 - 594
TRANSFER CASE - NV244
AN
TRANSFER CASE - NV244 (Continued)
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 82).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N·m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with Mopar® ATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N·m
(30-40 ft. lbs.).
(8) Lower vehicle.
Installer, Seal - 7884
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8033-A
Remover, Bushing - 8158
Installer, Bushing - 8157
Fig. 82 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
AN
TRANSFER CASE - NV244
21 - 595
FLUID (Continued)
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