Dodge Dakota (R1). Manual — part 723
(6) Install the screws to hold the transfer plate to
the valve body. Tighten the screws to 5.6 N·m (50 in.
lbs.).
(7) Install the accumulator pistons and springs
into the valve body in the location from which they
were removed. Note that all accumulators except the
overdrive have two springs. The overdrive accumula-
tor piston has only one spring.
(8) Position the accumulator cover onto the valve
body.
(9) Install the screws to hold the accumulator
cover onto the valve body. Tighten the screws to 4.5
N·m (40 in. lbs.).
(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install
the
solenoid
and
pressure
switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and
pressure switch assembly onto the valve body.
Tighten the screws to 5.7 N·m (50 in. lbs.). Tighten
the screws adjacent to the arrows cast into the bot-
tom of the transfer plate first.
(13) Position the detent spring onto the valve body.
(14) Install the screw to hold the detent spring
onto the valve body. Tighten the screw to 4.5 N·m (40
in. lbs.).
(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the
solenoid and pressure switch assembly. Replace seals
if cut or worn.
(2) Place TRS selector plate in the PARK position.
(3) Place the transmission in the PARK position.
(4) Lubricate seal on the solenoid and pressure
switch assembly connector with petroleum jelly.
(5) Position valve body in transmission and align
the manual lever on the valve body to the pin on the
transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N·m (105 in. lbs.) torque.
(8) Install new fluid filter on valve body. Tighten
filter screws to 4.5 N·m (40 in. lbs.) torque.
(9) Connect the solenoid and pressure switch
assembly connector.
(10) Install oil pan. Tighten pan bolts to 12 N·m
(105 in. lbs.) torque.
(11) Lower vehicle and fill transmission with
Mopar® ATF +4, type 9602, fluid.
(12) Check and adjust gearshift cable, if necessary.
21 - 536
AUTOMATIC TRANSMISSION - 45RFE
AN
VALVE BODY (Continued)
TRANSFER CASE - NV233
TABLE OF CONTENTS
page
page
TRANSFER CASE - NV233
TRANSFER CASE - NV233. . . . . . . . . . . . . . . 538
FLUID
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 561
FLUID DRAIN AND REFILL . . . . . . . . . . . . . . . 561
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 561
MODE SENSOR
REAR RETAINER BUSHING AND SEAL
SELECTOR SWITCH
SHIFT MOTOR
TRANSFER CASE - NV233
DESCRIPTION
The NV233 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV233 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
OPERATING RANGES
Transfer case operating ranges are:
• 2WD (2-wheel drive)
• 4HI (4-wheel drive)
• 4LO (4-wheel drive low range)
• NEUTRAL
The 2WD range is for use on any road surface at
any time.
The 4HI and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating
ranges
are
selected
with
a
dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver’s desire to
change operating ranges. The TCCM uses this input,
along with input from the transfer case mounted
mode sensor and information from the vehicle’s bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
AN
TRANSFER CASE - NV233
21 - 537
IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range sleeve.
The front output shaft is operated by a drive chain
that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is engaged/disengaged
by the mode fork, which operates the mode sleeve
and hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV233
DIAGNOSIS CHART
Condition
Possible Cause
Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case electronically
controlled shift system malfunction.
1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.
2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant.
3) Drain and refill transfer case with
the correct quantity of Mopar® ATF
+4, type 9602, Automatic
Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.
4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant.
1) Drain and refill transfer case with
the correct quantity of Mopar® ATF
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.
2) Repair or replace components as
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 538
TRANSFER CASE - NV233
AN
TRANSFER CASE - NV233 (Continued)
Condition
Possible Cause
Correction
Transfer case noisy while in, or
jumps out of, 4LO mode.
1) Transfer case not completely
engaged in 4LO position.
1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
2) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
2) Repair or replace components as
necessary.
3) Low range gear worn or
damaged.
3) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled.
1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear.
1) Extended operation in 4HI mode
on dry surfaces,
1) Operate vehicle in 2WD mode on
dry surfaces.
REMOVAL
(1) Shift transfer case into 2WD.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shafts for align-
ment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped.
(7) Disconnect front and rear propeller shafts at
transfer case.
(8) Disconnect transfer case shift motor and mode
sensor wire connectors.
(9) Disconnect transfer case vent hose.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission (Fig. 2).
(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove transfer case from under vehicle.
Fig. 2 Transfer Case Mounting - Typical
1 - MOUNTING STUDS
2 - TRANSFER CASE
3 - TRANSMISSION
AN
TRANSFER CASE - NV233
21 - 539
TRANSFER CASE - NV233 (Continued)
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