Page 2529 of 2889

REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and vacuum harness at
transfer case switch.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Remove rear crossmember.
(9) Mark front and rear propeller shafts for assem-
bly reference.
(10) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Move transfer case assembly rearward until
free of transmission output shaft.
(14) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
EXTENSION HOUSING
(1) Remove extension housing snap-ring access
cover.
(2) Remove bolts holding extension housing to rear
case half.
(3) Tap extension housing with plastic or rawhide
hammer to loosen sealant.
(4) Disengage extension housing snap-ring from
rear output shaft bearing.
(5) Separate extension housing from transfer case.
COMPANION FLANGE AND SHIFT LEVER
(1) Shift transfer case into NEUTRAL.
(2) Remove companion flange nut (Fig. 3). Discard
nut after removal. It is not reusable.
(3) Remove companion flange from front output
shaft. Use a suitable puller if flange can not be
removed by hand.
(4) Remove companion flange rubber seal from
front output shaft (Fig. 4).(5) Remove nut and washer that retain shift lever
to sector shaft. Then remove shift lever from shaft
(Fig. 5).
Fig. 3 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - SOCKET
Fig. 4 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 5 Shift Lever Removal
1 - SHIFT LEVER
2 - NUT/WASHER
21 - 894 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 2530 of 2889

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove output bearing retaining ring with
heavy duty snap-ring pliers.
(2) Remove output shaft bearing.
(3) Note position of bolts that attach rear case to
front case (Fig. 6). Some bolts/studs at ends of case
require flat washers. Mark position of these bolts
with paint or scriber.
(4) Remove rear case-to-front case bolts.
(5) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 7).(6) Unseat rear case from alignment dowels (Fig.
8).
(7) Remove rear case and oil pump assembly from
front case.
(8) Remove shift rail cup and spring (Fig. 9).
Fig. 6 Removing Case Attaching Bolts
1 - REAR CASE
2 - STUD
3 - NUT AND WASHER
4 - SOCKET
Fig. 7 Loosening Rear Case (Breaking Sealer Bead)
1 - SLOT
2 - REAR CASE
3-PRYTOOL
Fig. 8 Removing Rear Case From Alignment Dowels
1 - CASE DOWELS (2)
2 - REAR CASE
Fig. 9 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
BR/BETRANSFER CASE - NV241HD 21 - 895
TRANSFER CASE - NV241HD (Continued)
Page 2531 of 2889

(9) Remove front sprocket retaining ring (Fig. 10).
(10) Pull mainshaft, front sprocket, and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
11).
(11) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as an assembly.
SHIFT FORK AND MAINSHAFT
(1) Remove vacuum/indicator switch (Fig. 12).
(2) Loosen poppet plunger screw (Fig. 13).
(3) Remove poppet plunger screw and spring (Fig.
14). Note that screw has o-ring seal. Remove and dis-
card seal this seal.
Fig. 10 Removing Front Drive Sprocket Retaining
Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
Fig. 11 Removing Drive Chain And Front Sprocket
1 - CHAIN
2 - DRIVE SPROCKET
3 - FRONT SPROCKET
Fig. 12 Vacuum/Indicator Switch Removal
1 - 1-1/16º SOCKET
2 - INDICATOR SWITCH
Fig. 13 Loosening Poppet Plunger Screw
1 - POPPET PLUNGER SCREW
Fig. 14 Poppet Plunger Screw And Spring Removal
1 - POPPET PLUNGER SCREW
2 - O-RING
3 - PLUNGER SPRING
21 - 896 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 2532 of 2889
(4) Remove poppet plunger with magnet (Fig. 15).
(5) Remove front output shaft from bearing in case
(Fig. 16).
(6) Pull mainshaft assembly out of input gear, slid-
ing clutch and case (Fig. 17).
(7) Remove mode fork, sliding clutch and shift rail
as assembly (Fig. 18). Note which way clutch fits in
fork (long side of clutch goes to front).
Fig. 15 Poppet Plunger Removal
1 - MAGNET
2 - POPPET PLUNGER
Fig. 16 Front Output Shaft Removal
1 - BALL BEARING
2 - FRONT OUTPUT SHAFT
Fig. 17 Mainshaft Assembly Removal
1 - SLIDING CLUTCH
2 - MODE FORK
3 - MAINSHAFT ASSEMBLY
Fig. 18 Mode Fork, Shift Rail And Sliding Clutch
Removal
1 - MODE FORK
2 - SHIFT RAIL
3 - SLIDING CLUTCH
BR/BETRANSFER CASE - NV241HD 21 - 897
TRANSFER CASE - NV241HD (Continued)
Page 2533 of 2889
(8) Remove sliding hub retaining ring (Fig. 19).
(9) Remove range fork and sliding hub as an
assembly (Fig. 20).
(10) Remove shift sector (Fig. 21).
(11) Remove shift sector shaft nylon retainer and
o-ring from shaft bore in front case (Fig. 22).
Fig. 19 Sliding Hub Retaining Ring Removal
1 - RETAINING RING
2 - RANGE FORK
3 - SLIDING HUB
Fig. 20 Range Fork And Sliding Hub Removal
1 - SUPPORT SLEEVE
2 - RANGE FORK
Fig. 21 Shift Sector Removal
1 - SHIFT SECTOR
2 - SECTOR SHAFT
Fig. 22 Removing Sector Shaft O-Ring And Retainer
1 - SHAFT BORE
2 - NYLON RETAINING RING
3 - SECTOR SHAFT O-RING
21 - 898 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 2534 of 2889

MAINSHAFT
(1) Remove retaining ring that secures synchro-
nizer hub on mainshaft (Fig. 23). Use standard
(instead of parallel jaw) snap-ring pliers to remove
this retaining ring.
(2) Remove synchronizer hub (Fig. 24).
(3) Inspect synchronizer hub struts and springs. If
struts appear worn, remove struts and springs from
hub. Note position of springs for installation refer-
ence (Fig. 25).
(4) Remove brass stop ring (Fig. 26). Discard stop
ring if worn, cracked, or any teeth are missing.
(5) Remove drive sprocket (Fig. 27).
Fig. 23 Synchronizer Hub Retaining Ring Removal
1 - SYNCHRONIZER HUB
2 - RETAINING RING
Fig. 24 Synchronizer Hub Removal
1 - SYNCHRONIZER HUB
2 - MAINSHAFT
Fig. 25 Synchronizer Strut And Spring Removal
1 - SYNCHRONIZER STRUTS
2 - SYNCHRONZER HUB
3 - SYNCHRONIZER SPRINGS
Fig. 26 Synchronizer Stop Ring Removal
1 - DRIVE SPROCKET
2 - STOP RING
Fig. 27 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
BR/BETRANSFER CASE - NV241HD 21 - 899
TRANSFER CASE - NV241HD (Continued)
Page 2535 of 2889

INPUT AND PLANETARY GEAR
(1) Remove input bearing retainer bolts (Fig. 28).
(2) Loosen bearing retainer with pry tool. Insert
tool in retainer slot as shown (Fig. 29). Then remove
retainer.
(3) Remove input gear retaining ring with heavy
duty parallel jaw snap-ring pliers (Fig. 30).
(4) Tap input gear out of bearing with plastic mal-
let (Fig. 31).
(5) Remove input gear and planetary/PTO gear as
assembly (Fig. 32).
INPUT AND PLANETARY GEAR
The only removable parts in the planetary assem-
bly are the snap-rings, needle bearing, thrust wash-
ers, lock ring, input gear, and support sleeve.The
planetary carrier, PTO gear, planetary pinions,
and remaining planetary components are fixed
parts and are serviced as an assembly.(1) Position planetary assembly so PTO gear is on
bench (Fig. 33).
(2) Remove retaining ring that secures input gear
and lock ring in planetary assembly.
(3) Remove lock ring and front thrust washer from
carrier (Fig. 34). Note that lock ring and thrust
washer are both tabbed.
(4) Remove input gear from planetary carrier (Fig.
35). Lift gear straight up and out of carrier.
Fig. 28 Removing Input Bearing Retainer Bolts
1 - BEARING RETAINER
2 - INPUT GEAR
Fig. 29 Loosening/Removing Input Bearing Retainer
1 - BEARING RETAINER
2 - SLOT
3-PRYTOOL
Fig. 30 Removing Input Gear Retaining Ring
1 - RETAINING RING
2 - INPUT BEARING
3 - INPUT GEAR
Fig. 31 Removing Input Gear
1 - BEARING
2 - INPUT GEAR
3 - PLASTIC MALLET
21 - 900 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 2536 of 2889
Fig. 32 Input Gear And Planetary Assembly
Removal
1 - INPUT GEAR
2 - PLANETARY AND PTO GEAR ASSEMBLY
Fig. 33 Removing Lock Ring/Input Gear Retaining
Ring
1 - INPUT GEAR
2 - PLANETARY ASSEMBLY
3 - PTO GEAR
4 - RETAINING RING
Fig. 34 Planetary Lock Ring And Front Thrust
Washer Removal
1 - THRUST WASHER
2 - PLANETARY
3 - LOCK RING
Fig. 35 Removing Input Gear From Planetary Carrier
1 - INPUT GEAR
2 - PLANETARY CARRIER
BR/BETRANSFER CASE - NV241HD 21 - 901
TRANSFER CASE - NV241HD (Continued)