Dodge Dakota (R1). Manual — part 724
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
REAR RETAINER AND OIL PUMP
(1) Remove extension housing bolts.
(2) Tap extension housing with plastic or rawhide
mallet to loosen sealer (Fig. 3).
(3) Separate extension housing from rear retainer.
(4) Remove rear bearing snap-ring (Fig. 4).
(5) Remove bolts holding rear retainer to rear case
half.
(6) Loosen rear retainer with pry tool to break
sealer bead. Pry only against retainer boss as shown
(Fig. 5).
(7) Disengage oil pickup tube from oil pump and
remove oil pump assembly (Fig. 6).
(8) Remove pick-up tube o-ring from oil pump (Fig.
7), if necessary. Do not disassemble the oil pump, it
is not serviceable.
Fig. 3 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 4 Remove Rear Bearing Snap-Ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 5 Loosening Rear Retainer
1 - REAR RETAINER
2 - TAB (2)
3 - SCREWDRIVER
4 - TAB
Fig. 6 Oil Pump Removal
1 - OIL PUMP
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TRANSFER CASE - NV233
AN
TRANSFER CASE - NV233 (Continued)
COMPANION FLANGE AND SHIFT MOTOR
ASSEMBLY
(1) Remove front companion flange nut with a
socket and impact wrench
(2) Remove the front companion flange. If the
flange is difficult to remove by hand, remove it with
bearing splitter, or with standard two jaw puller. Be
sure puller tool is positioned on the flange and not on
the slinger, as slinger will be damaged.
(3) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(4) Remove the bolts (Fig. 8) which hold the shift
motor and mode sensor assembly to the transfer
case.
(5) Remove the shift motor and mode sensor
assembly from the transfer case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(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.
9).
(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. 10).
(4) Remove rear case from front case.
Fig. 7 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
Fig. 8 Remove the Shift Motor and Mode Sensor
Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
Fig. 9 Rear Case Alignment Bolt Locations
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 10 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
AN
TRANSFER CASE - NV233
21 - 541
TRANSFER CASE - NV233 (Continued)
(5) Remove oil pickup tube from rear case (Fig.
11).
(6) Remove mode fork spring (Fig. 12).
(7) Pull front output shaft upward and out of front
output shaft bearing (Fig. 13).
(8) Remove front output shaft and chain.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 14).
(2) Remove mainshaft from mode sleeve and input
gear pilot bearing.
Fig. 11 Oil Pickup Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 12 Mode Fork Spring Removal
1 - MODE SPRING
Fig. 13 Remove Front Output Shaft And Drive Chain
1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING
Fig. 14 Detent Plug, Spring, And Plunger Removal
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
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TRANSFER CASE - NV233
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TRANSFER CASE - NV233 (Continued)
(3) Remove mode fork and sleeve as an assembly
(Fig. 15). 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. 16). Note fork position for installation reference.
(5) Remove shift sector from front case (Fig. 17).
(6) Remove shift sector o-ring (Fig. 18).
Fig. 15 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 16 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 17 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 18 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
AN
TRANSFER CASE - NV233
21 - 543
TRANSFER CASE - NV233 (Continued)
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