Page 2505 of 2889

(b) Start seal in bore with light taps from ham-
mer (Fig. 49). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.(c) Remove installer and verify that seal is
recessed the proper amount (Fig. 50). Seal should
be 2.03 to 2.5 mm (0.080 to 0.100 in.) below top
edge of seal bore in front case. This is correct final
seal position.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. The
seal could loosen, or become cocked if not seated
to recommended depth.
(9) Remove seal from front bearing retainer with
suitable pry tool.
Fig. 47 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 48 Front Output Shaft Bearing Installation
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
Fig. 49 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
Fig. 50 Checking Front Output Seal Installation
Depth
1 - CORRECT SEAL DEPTH IS 2.03-2.5 mm (0.080-0.100 in.)
BELOW TOP EDGE OF BORE
2 - FRONT CASE SHAFT BORE
3 - FRONT OUTPUT SEAL
21 - 870 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)
Page 2506 of 2889

(10) Install new oil seal in front bearing retainer
with Installer 7884 (Fig. 51).
(11)
Remove seal from oil pump with suitable pry tool.
(12) Install new seal in oil pump with Installer
7888 (Fig. 52).
(13) Remove input gear pilot bearing by inserting
a suitably sized drift into the splined end of the input
gear and driving the bearing out with the drift and a
hammer (Fig. 53).
(14) Install new pilot bearing with Plug C-293-3.(15) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 54).
Fig. 54 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 51 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 52 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
Fig. 53 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
BR/BETRANSFER CASE - NV241LD 21 - 871
TRANSFER CASE - NV241LD (Continued)
Page 2507 of 2889

(16) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 55). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 56).INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 57)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 57). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
Fig. 55 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 56 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 57 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
21 - 872 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)
Page 2508 of 2889

(6) Align and install low range/input gear assem-
bly in front case (Fig. 58). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 59).
(8) Clean gasket sealer residue from retainer and
inspect retainer for cracks or other damage.
(9) Applya3mm(1/8 in.) bead of MopartGasket
Maker, or equivalent silicone adhesive, to sealing
surface of retainer.
(10) Align cavity in seal retainer with fluid return
hole in front of case.CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying MoparTGas-
ket Maker, or equivalent silicone adhesive sealer.
Seal failure and fluid leak can result.
(11) Install bolts to hold retainer to transfer case
(Fig. 60). Tighten to 21 N´m (16 ft. lbs.) of torque.
SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install drive sprocket on mainshaft (Fig. 61).
Fig. 58 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
Fig. 59 Install Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 60 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 61 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
BR/BETRANSFER CASE - NV241LD 21 - 873
TRANSFER CASE - NV241LD (Continued)
Page 2509 of 2889

(3) Install brass stop ring on drive sprocket (Fig.
62).
(4) Install 3 synchronizer struts and 2 springs in
hub as follows:
(a) Insert first strut in hub (Fig. 63). Strut
shoulders rest (and slide) on sides hub slot as
shown.(b) Insert hooked end of first spring in center of
strut to secure it. Then work spring into hub (Fig.
64).
(c) Press spring inward and insert last two
struts in hub slots. Be sure spring is positioned
under struts to properly secure them (Fig. 65).
(d) Turn hub over and install remaining spring
in hub. Position hooked end of second spring oppo-
site the first spring's hooked end.
Fig. 63 Installing First Synchronizer Strut And
Spring
1 - FIRST STRUT
2 - SYNCHRONIZER HUB
3 - SPRING
Fig. 62 Synchronizer Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKET
Fig. 64 Synchronizer Spring Installation
1 - STRUT SHOULDER
2 - SPRING (SEATED IN STRUT)
3 - HUB
Fig. 65 Correct Position Of Struts And Springs
1 - STRUTS
2 - SPRING
21 - 874 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)
Page 2510 of 2889

(5) Install assembled synchronizer hub on main-
shaft (Fig. 66). Hub has shoulder on one side which
goes toward sprocket (rear of shaft). Flat side of hub
faces front of shaft.
(6) Install synchronizer hub retaining ring (Fig.
67). Be sure ring is fully seated before proceeding.
(7) Install sliding clutch (sleeve) on synchronizer
hub (Fig. 68).
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. 69). If the clutch is
installed so a gap between splines is aligned with
one or more struts, gear clash will result.
(8) 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.
(9) Lubricate mainshaft components with trans-
mission fluid.
Fig. 66 Synchronizer Hub Installation
1 - SYNCHRONIZER HUB (SHOULDER SIDE DOWN)
2 - STOP RING AND SPROCKET
Fig. 67 Synchronizer Hub Retaining Ring
Installation
1 - SNAP-RING PLIERS
2 - SYNCHRONIZER HUB
3 - HUB RETAINING RING
Fig. 68 Sliding Clutch Installation
1 - SLIDING CLUTCH
2 - SYNCHRONIZER HUB
BR/BETRANSFER CASE - NV241LD 21 - 875
TRANSFER CASE - NV241LD (Continued)
Page 2511 of 2889
(10) Lubricate sector shaft with transmission fluid
and install shift sector in case (Fig. 70). Position slot
in sector so it will be aligned with shift fork pin
when shift forks are installed.
(11) Assemble and install range fork and hub (Fig.
71). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install mode fork and shift rail in sliding
clutch (Fig. 72).
Fig. 69 Correct Alignment Of Struts And Sliding
Clutch
1 - SLEEVE TOOTH ALIGNED WITH STRUT
2 - STRUT
3 - SLEEVE TOOTHNOTALIGNED WITH STRUT
4 - STRUT
Fig. 70 Shift Sector Installation
1 - SHIFT SECTOR
Fig. 71 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 72 Assembling Mode Fork And Mainshaft
1 - SLIDING CLUTCH
2 - MODE FORK AND SHIFT RAIL
21 - 876 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)
Page 2512 of 2889

(14) Install mainshaft/mode fork assembly (Fig.
73). Guide mainshaft through hub and into input
gear and shift rail through range fork and into case
bore.
(15) Install new o-ring on vacuum/indicator switch,
if necessary.Install vacuum/indicator switch (Fig. 74).
Tighten switch to 20-34 N´m (15-25 ft. lbs.) torque.
(16) Install new sector shaft o-ring and o-ring
retainer in sector shaft bore (Fig. 75). Lubricate
o-ring with transmission fluid or petroleum jelly after
installation.(17) Install shift lever on sector shaft (Fig. 76).
(18) 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. 73 Installing Mainshaft And Mode Fork
Assembly
1 - MAINSHAFT AND MODE FORK ASSEMBLY
2 - SHIFT RAIL
3 - RANGE FORK
Fig. 74 Vacuum/Indicator Switch Installation
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 75 Sector Shaft O-Ring And Retainer
Installation
1 - SECTOR SHAFT BORE
2 - O-RING
3 - O-RING RETAINER
Fig. 76 Shift Lever Installation
1 - SHIFT LEVER
2 - NUT/WASHER
BR/BETRANSFER CASE - NV241LD 21 - 877
TRANSFER CASE - NV241LD (Continued)