2001 DODGE RAM lock

(6) Install sliding clutch (sleeve) on synchronizer
hub (Fig. 71).
CAUTION: The sliding clutch must be correctly
positioned to ensure proper shifting. Position the
clutch on the hub so a clutch spline is centered
over each strut as shown (Fig. 72). If the clutch is
installed so a gap between splines is aligned with
one or more struts, gear clash will result.
SHIFT FORKS AND MAINSHAFT
(1) Support front case on wood blocks so case inte-
rior is facing up. Place blocks between mounting
studs on forward surface of case. Be sure blocks will
not interfere with input gear installation.
(2) Lubricate mainshaft components with trans-
mission fluid.
(3) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 73). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
Fig. 71 Sliding Clutch Installation
1 - SLIDING CLUTCH
2 - SYNCHRONIZER HUB
Fig. 72 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTHNOTALIGNED WITH STRUT
4 - STRUT
Fig. 73 Shift Sector Installation
1 - SHIFT SECTOR
2 - SECTOR SHAFT
21 - 912 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(7) Install mainshaft/mode fork assembly (Fig. 78).
Guide mainshaft through hub and into input gear
and shift rail through range fork and into case bore.
(8) Install new o-ring on vacuum/indicator switch,
if necessary. Install vacuum/indicator switch (Fig.
79). Tighten switch to 20-34 N´m (15-25 ft. lbs.)
torque.
(9) Install new sector shaft o-ring and o-ring
retainer in sector shaft bore (Fig. 80). Lubricate
o-ring with transmission fluid or petroleum jelly after
installation.(10) Install shift lever on sector shaft (Fig. 81).
(11) Install washer and nut on sector shaft to
secure shift lever. Apply 1-2 drops MopartLock N'
Seal, or equivalent, to nut threads before installation.
Then tighten nut to 27-34 N´m (20-25 ft. lbs.) torque.
Fig. 78 Installing Mainshaft And Mode Fork
Assembly
1 - MAINSHAFT AND MODE FORK ASSEMBLY
2 - SHIFT RAIL
3 - RANGE FORK
Fig. 79 Vacuum/Indicator Switch Installation
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 80 Sector Shaft O-Ring And Retainer
Installation
1 - SECTOR SHAFT BORE
2 - O-RING
3 - O-RING RETAINER
Fig. 81 Shift Lever Installation
1 - SHIFT LEVER
2 - NUT/WASHER
21 - 914 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(8) Check stud at end of case halves (Fig. 94). If
stud was loosened or came out during disassembly,
apply LoctiteŸ 242 to stud threads and reseat stud
in case.
(9) Apply LoctiteŸ 242 to remainder of rear case-
to-front case bolt threads and install bolts. Be sure
lock washers are used on studs/bolts at case ends.
Tighten bolts, or stud nuts as follows:
²flange head bolts to 47-61 N´m (35-45 ft. lbs.)
²all other bolts/nuts to 27-34 N´m (20-25 ft. lbs.)
(10) Install oil pump retaining ring on mainshaft
(Fig. 95).
(11) Install rear output bearing and snap-ring to
output shaft.
COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 96).
(2) Install companion flange on front shaft (Fig.
97). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
EXTENSION HOUSING AND PTO COVER
(1) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could be dis-
placed into oil pump.
(2) Position extension housing over output shaft.
(3) Spread extension housing retaining ring and
seat extension housing on rear case. Verify that the
retaining ring is seated in output shaft rear bearing.
(4) Install retaining ring access cover.
(5) Apply MopartSilicone Sealer, or equivalent, to
threads of extension housing bolts. Then install bolts
finger tight.
(6) Tighten extension housing bolts to 27-34 N´m
(20-25 ft. lbs.) torque.
Fig. 94 Washer Installation On Case Stud And
Dowel Bolts
1 - CASE STUD/BOLT
2 - WASHER
Fig. 95 Oil Pump Retaining Ring Installation
1 - RETAINING RING
2 - OIL PUMP
Fig. 96 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 97 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
21 - 918 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(7) Apply MopartSilicone Sealer to mating surface
of PTO cover and to cover bolt shanks and underside
of bolt heads. Then install and tighten bolts to 27-34
N´m (20-25 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Install rear crossmember.(4) Remove jack stand from under transmission.
(5) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Connect vacuum harness and vent hose.
(7) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(8) Adjust shift linkage, if necessary.
(9) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(10) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(11) Lower vehicle
SPECIFICATIONS
TRANSFER CASE
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Bolt, Diff. Case 17-27 15-24 -
Plug, Drain/Fill 40-45 30-40 -
Bolt, Extension Housing 35-46 26-34 -
Bolt, Front Brg. Retainer 16-27 12-24 -
Bolt, Case Half 35-46 26-34 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 20-25 -
Bolt, Rear Retainer 35-46 26-34 -
Nuts, Mounting 30-41 20-30 -
Bolts, U-Joint 19 17 -
Vacuum Switch 20-34 15-25 -
BR/BETRANSFER CASE - NV241HD 21 - 919
TRANSFER CASE - NV241HD (Continued)

SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Remove transfer case shifter knob cap.
(3) Remove nut holding shifter knob to shift lever.
(4) Remove shifter knob.
(5) Remove the shift boot from the shifter bezel.
(6) Remove the bolts securing the shifter mecha-
nism to the floor pan along the driver's side of the
transmission tunnel (Fig. 107).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(9) Remove the nuts holding the shifter mecha-
nism to the underside of the floor pan.
(10) Separate shift lever mechanism from the vehi-
cle.
INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 108).
(2) Position shift lever on vehicle.
(3) Install nuts to hold shift lever to the underside
of the body.
(4) Install trunnion to shift lever, if necessary.
(5) Install shift rod to trunnion, if necessary.
(6) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(7) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(8) Lower vehicle.
(9) Install the bolts to hold the shifter mechanism
to the floor pan.
(10) Install the transfer case shifter bezel.
(11) Install the shifter boot and the shifter knob
onto the shifter lever.
(12) Install nut to hold shifter knob to shift lever.
(13) Install shifter knob cap.
(14) Verify transfer case operation.
Fig. 107 Transfer Case Shifter
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
Fig. 108 Shifter Adjustment
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
21 - 924 TRANSFER CASE - NV241HDBR/BE

ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion (Fig.
109).
(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion. Lubricate the shift rod
and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H
detent position. The 2H detent position on the trans-
fer case shift arm is the second position from full for-
ward.(6) Align the adjustment locating hole on the lower
shifter lever with the adjustment channel on the
shifter bracket assembly (Fig. 110).
(7) Insert an appropriately sized pin through into
the adjustment channel and through the locating
hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N´m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans-
fer case shifts into and operates properly in all
ranges.
Fig. 109 Shift Rod Lock Bolt Location
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
Fig. 110 Shifter Adjustment Location
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
BR/BETRANSFER CASE - NV241HD 21 - 925
SHIFT LEVER (Continued)

DESCRIPTION
Radial-ply tires improve handling, tread life and
ride quality, and decrease rolling resistance.
Radial-ply tires must always be used in sets of
four. Under no circumstances should they be used on
the front only. They may be mixed with temporary
spare tires when necessary. A maximum speed of 50
MPH is recommended while a temporary spare is in
use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
The use of oversized tires, either in the front or
rear of the vehicle, can cause vehicle drive train fail-
ure. This could also cause inaccurate wheel speed
signals when the vehicle is equipped with Anti-Lock
Brakes.
The use of tires from different manufactures on the
same vehicle is NOT recommended. The proper tire
pressure should be maintained on all four tires.
DESCRIPTION
Where speed limits allow the vehicle to be driven
at high speeds, correct tire inflation pressure is very
important. For speeds up to and including 120 km/h
(75 mph), tires must be inflated to the pressures
shown on the tire placard. For continuous speeds inexcess of 120 km/h (75 mph), tires must be inflated
to the maximum pressure specified on the tire side-
wall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.
DESCRIPTION
The original equipment tires provide a proper bal-
ance of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DESCRIPTION
Under inflation will cause rapid shoulder wear, tire
flexing, and possible tire failure (Fig. 12) .
Over inflation will cause rapid center wear and
loss of the tire's ability to cushion shocks (Fig. 13) .
Improper inflation can cause:
²Uneven wear patterns
²Reduced tread life
²Reduced fuel economy
²Unsatisfactory ride
²Vehicle drift
For proper tire pressure specification refer to the
Tire Inflation Pressure Chart provided with the vehi-
cles Owners Manual. A Certification Label on the
drivers side door pillar provides the minimum tire
and rim size for the vehicle. The label also list the
cold inflation pressure for these tires at full load
operation
Fig. 11 Tire Identification
22 - 6 TIRES/WHEELSBR/BE
TIRES (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DESCRIPTION............................1
WARNING...............................1
DIAGNOSIS AND TESTING..................2
WATER LEAKS..........................2
WIND NOISE...........................3
SPECIFICATIONS.........................4
DECKLID/HATCH/LIFTGATE/TAILGATE........62
DOOR - FRONT..........................67DOOR - CARGO.........................77
EXTERIOR..............................86
HOOD.................................99
INSTRUMENT PANEL SYSTEM.............104
INTERIOR.............................118
PAINT................................129
SEATS................................131
STATIONARY GLASS.....................145
WEATHERSTRIP/SEALS..................152
BODY
DESCRIPTION ± PUSH-IN FASTENERS
DaimlerChrysler Corporation uses many different
types of push-in fasteners to secure the interior and
exterior trim to the body. Most of these fasteners can
be reused to assemble the trim during various repair
procedures. At times, a push-in fastener cannot be
removed without damaging the fastener or the com-
ponent it is holding. If it is not possible to remove a
fastener without damaging a component or body, cut
or break the fastener and use a new one when
installing the component. Never pry or pound on a
plastic or pressed-board trim component. Using a
suitable fork-type prying device, pry the fastener
from the retaining hole behind the component being
removed. When installing, verify fastener alignment
with the retaining hole by hand. Push directly on or
over the fastener until it seats. Apply a low-force pull
to the panel to verify that it is secure.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges holding the component in
place.
DESCRIPTION ± LOCK CYLINDERS
Ignition, door, deck lid, and rear hatch lock cylin-
ders are all codable to the key. Lock barrels, tum-
blers, and tumbler springs are available to allow the
technician to change replacement locks cylinders to
match the customer's original key set. See the appro-
priate section in this manual for lock cylinder
removal. See the Moparž catalogue for part numbers
and lock coding procedures.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL ± BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE THAT
IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use when
welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
ish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
BR/BEBODY 23 - 1