Dodge Dakota (R1). Manual — part 726
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 33). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 34). The
mode and range fork pads are serviceable and can be
replaced if necessary.
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. 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 show any sign of
wear or damage.
FRONT OUTPUT SHAFT/FLANGE/DRIVE CHAIN
Check condition of the seal contact surfaces on the
companion flange slinger. This surface must be clean
and smooth to ensure proper seal life. Replace the
flange 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. 35)
FRONT/REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. 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
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoil® stain-
less steel inserts if required.
Fig. 33 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
Fig. 34 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
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TRANSFER CASE - NV233
AN
TRANSFER CASE - NV233 (Continued)
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.
ASSEMBLY
Lubricate transfer case components with Mopar®
ATF +4, type 9602, Automatic Transmission Fluid or
petroleum jelly (where indicated) during assembly.
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
with pry tool (Fig. 36).
(2) Remove bearing retaining ring with screw-
driver (Fig. 37).
Fig. 37 Front Output Shaft Bearing Retaining Ring
Removal
1 - SCREWDRIVERS
2 - SNAP-RING
3 - FRONT OUTPUT SHAFT BEARING
4 - FRONT CASE
Fig. 36 Front Output Seal Removal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRY TOOL
Fig. 35 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
AN
TRANSFER CASE - NV233
21 - 549
TRANSFER CASE - NV233 (Continued)
(3) Remove bearing with Tool Handle C-4171 and
Tool 5065 (Fig. 38).
(4) Install front output shaft front bearing in case
with Tool Handle C-4171 and Installer 5064 (Fig. 39).
(5) Install output shaft front bearing retaining
ring (Fig. 40). Start ring into place by hand. Then
use small screwdriver to work ring into case groove.
Be sure ring is fully seated before proceeding.
(6) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on
seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 41). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
Fig. 38 Front Output Shaft Bearing Removal
1 - FRONT CASE
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 5065
Fig. 39 Front Output Shaft Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
Fig. 40 Installing Front Output Shaft Bearing
Retaining Ring
1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
Fig. 41 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
21 - 550
TRANSFER CASE - NV233
AN
TRANSFER CASE - NV233 (Continued)
(7) Remove the output shaft rear bearing with the
screw and jaws from Remover L-4454 and Cup 8148
(Fig. 42).
(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 43). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 44).
Fig. 42 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 43 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 44 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
AN
TRANSFER CASE - NV233
21 - 551
TRANSFER CASE - NV233 (Continued)
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