Dodge Dakota (R1). Manual — part 733
(12) Remove low range fork and hub (Fig. 25).
(13) Remove shift sector.
(14) Remove shift sector o-ring (Fig. 26).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Remove front bearing retainer bolts.
(2) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 27). Position
screwdriver in slots cast into retainer.
(3) Remove input gear snap-ring (Fig. 28).
Fig. 25 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 26 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 27 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
Fig. 28 Remove the Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
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TRANSFER CASE - NV244
AN
TRANSFER CASE - NV244 (Continued)
(4) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829-A
(Fig. 29).
(5) Remove low range gear snap-ring (Fig. 30).
(6) Remove input gear retainer, thrust washers,
and input gear from low range gear (Fig. 31).
(7) Inspect low range annulus gear (Fig. 32). Gear
is not a serviceable component. If damaged,
replace gear and front case as an assembly.
Fig. 29 Input And Low Range Gear Assembly
Removal
1 - INPUT-LOW RANGE GEARS
2 - SPECIAL TOOL 7829-A
3 - SPECIAL TOOL C-4171
Fig. 30 Remove the Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
Fig. 31 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 32 Inspecting Low Range Annulus Gear
1 - LOW RANGE ANNULUS GEAR
AN
TRANSFER CASE - NV244
21 - 577
TRANSFER CASE - NV244 (Continued)
(8) Remove oil seals from the following compo-
nents:
• front bearing retainer.
• rear retainer.
• oil pump.
• case halves.
DIFFERENTIAL
(1) Mark differential case halves for reference.
(2) Remove differential case bolts.
(3) Invert differential on workbench.
(4) Separate top case from bottom case. Use slots
in case halves to pry them apart (Fig. 33).
(5) Remove thrust washers and planet gears from
case pins (Fig. 34).
(6) Remove mainshaft and sprocket gears from
bottom case (Fig. 35). Note gear position for reference
before separating them.
Fig. 33 Separating Differential Case Halves
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig. 34 Planet Gears And Thrust Washer Removal
1 - BOTTOM CASE
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
Fig. 35 Mainshaft And Sprocket Gear Removal
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
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TRANSFER CASE - NV244
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TRANSFER CASE - NV244 (Continued)
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. 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. 36). 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.
Fig. 36 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 - NV244
21 - 579
TRANSFER CASE - NV244 (Continued)
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