Dodge Dakota (R1). Manual — part 725
MAINSHAFT
(1) Remove mode hub retaining ring with heavy
duty snap-ring pliers (Fig. 19).
(2) Slide mode hub off mainshaft (Fig. 20).
(3) Slide drive sprocket off mainshaft (Fig. 21).
INPUT GEAR AND LOW RANGE GEAR
(1) Remove front bearing retainer attaching bolts
(Fig. 22).
Fig. 22 Front Bearing Retainer Bolts
1 - FRONT CASE
2 - FRONT BEARING RETAINER
3 - RETAINER BOLTS
Fig. 19 Mode Hub Retaining Ring Removal
1 - MODE HUB
2 - SNAP-RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING
Fig. 20 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 21 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
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TRANSFER CASE - NV233
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TRANSFER CASE - NV233 (Continued)
(2) Remove front bearing retainer. Pry retainer
loose with pry tool positioned in slots at each end of
retainer (Fig. 23).
(3) Remove front bearing retainer seal. Tap seal
out with drift and hammer.
(4) Remove input gear retaining ring with heavy
duty snap-ring pliers (Fig. 24)
(5) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 25). Tap gear out of bearing with plastic
mallet if necessary.
INPUT AND LOW RANGE GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 26).
Fig. 26 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 23 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
Fig. 24 Removing Input Gear Retaining Ring
1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
3 - SNAP-RING PLIERS
Fig. 25 Input Gear And Planetary Carrier Removal
1 - INPUT AND LOW RANGE GEAR ASSEMBLY
AN
TRANSFER CASE - NV233
21 - 545
TRANSFER CASE - NV233 (Continued)
(2) Remove retainer (Fig. 27).
(3) Remove front tabbed thrust washer (Fig. 28).
(4) Remove input gear (Fig. 29).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 30).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3M™ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket (Fig. 31). Minor nicks and
scratches can be smoothed with an oilstone. However,
replace any part that is damaged.
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. 32). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
Fig. 27 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 28 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 29 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 30 Rear Tabbed Thrust Washer
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
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TRANSFER CASE - NV233
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TRANSFER CASE - NV233 (Continued)
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.
Fig. 31 Mainshaft, Mode Hub, And Drive Sprocket
1 - MODE HUB
3 - MAINSHAFT
2 - DRIVE SPROCKET
4 - MODE HUB RETAINING RING
Fig. 32 Input Gear and Carrier Components
1 - PLANETARY CARRIER
4 - CARRIER LOCK RING
2 - REAR THRUST WASHER
5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER
6 - INPUT GEAR
AN
TRANSFER CASE - NV233
21 - 547
TRANSFER CASE - NV233 (Continued)
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