Dodge Dakota (R1). Manual — part 736
(9) Install differential (Fig. 64). Do not displace
mainshaft bearings when installing differential.
(10) Install differential snap-ring (Fig. 65).
(11) Install intermediate clutch shaft (Fig. 66).
(12) Install clutch shaft thrust ring (Fig. 67).
Fig. 64 Differential Installation
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 65 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 66 Installing Intermediate Clutch Shaft
1 - INTERMEDIATE CLUTCH SHAFT
Fig. 67 Installing Clutch Shaft Thrust Ring
1 - CLUTCH SHAFT THRUST RING
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TRANSFER CASE - NV244
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TRANSFER CASE - NV244 (Continued)
(13) Install clutch shaft snap-ring (Fig. 68).
(14) Inspect mode fork assembly (Fig. 69). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 69). Replace
worn or damaged components.
(15) Install mode sleeve in mode fork (Fig. 70).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(16) Install mode fork and mainshaft assembly in
case (Fig. 71). Rotate mainshaft slightly to engage
shaft with low range gears.
Fig. 68 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 69 Mode Fork Assembly Inspection
1 - SLIDER
2 - MODE FORK
3 - BUSHING/SPRING
4 - TUBE
5 - PADS
Fig. 70 Installing Mode Fork And Sleeve
1 - MAINSHAFT
2 - SLEEVE
3 - MODE FORK ASSEMBLY
AN
TRANSFER CASE - NV244
21 - 589
TRANSFER CASE - NV244 (Continued)
(17) Rotate mode fork pin into shift sector slot.
(18) Install shift rail (Fig. 72). Be sure rail is
seated in both shift forks.
(19) Install detent plunger, detent spring, and
detent plug in case (Fig. 73).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install front output shaft (Fig. 74).
(2) Install drive chain (Fig. 74). Engage chain with
front output shaft sprocket teeth.
(3) Install drive sprocket (Fig. 74). Engage drive
sprocket teeth with chain. Then engage sprocket
splines with mainshaft splines.
Fig. 72 Shift Rail Installation
1 - SHIFT RAIL
2 - MODE FORK
Fig. 71 Assembled Mainshaft And Mode Fork
Installation
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 73 Detent Pin, Spring And Plug Installation
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
Fig. 74 Drive Chain And Sprocket Installation
1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
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TRANSFER CASE - NV244
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TRANSFER CASE - NV244 (Continued)
(4) Install drive sprocket snap-ring (Fig. 75).
OIL PUMP AND REAR CASE
(1) Insert oil pickup tube in oil pump and attach
oil screen and connector hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 76). Be sure screen is seated in case slot as
shown.
(2) Clean the transfer case magnet.
(3) Install magnet in front case pocket (Fig. 77).
(4) Apply 3 mm (1/8 in.) wide bead of Mopar® Gas-
ket Maker, or equivalent silicone adhesive sealer, to
seal surface of front case.
(5) Align and install rear case on front case. Be
sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
(6) Install and tighten front case to rear case bolts
to 27-34 N·m (20-25 ft. lbs.) torque. Be sure to
install a washer under each bolt used at case
dowel locations.
Fig. 75 Drive Sprocket Snap-Ring Installation
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 76 Oil Screen And Pickup Tube Installation
1 - OIL PUMP
2 - OIL SCREEN
3 - CONNECTOR
4 - PICKUP TUBE
Fig. 77 Installing Case Magnet
1 - MAGNET
AN
TRANSFER CASE - NV244
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TRANSFER CASE - NV244 (Continued)
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