2001 DODGE RAM ECU

INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 101). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange seal on front shaft
(Fig. 102).
(3) Install companion flange on front shaft (Fig.
103). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
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. 104).
(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.
Fig. 101 Front Output Seal Installation
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 102 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 103 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
21 - 852 TRANSFER CASE - NV231HDBR/BE
FRONT OUTPUT SHAFT SEAL (Continued)

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.
REAR EXTENSION, RETAINER, AND REAR CASE
(1) Remove rear extension bolts (Fig. 2).(2) Remove rear extension housing (Fig. 3). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 4).
Fig. 2 Rear Extension Bolt Removal
1 - SOCKET
2 - REAR EXTENSION
Fig. 3 Rear Extension Housing Removal
1 - SEAL
2 - REAR EXTENSION HOUSING
3 - REAR RETAINER
Fig. 4 Removing Output Bearing Retaining Ring
1 - OUTPUT BEARING
2 - RETAINING RING
3 - REAR RETAINER
21 - 858 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(9) Remove range fork and hub as an assembly
(Fig. 24). Note fork position for installation reference.
(10) Remove shift sector (Fig. 25).
(11) Remove shift sector shaft nylon retainer and
O-ring from shaft bore in front case (Fig. 26).
MAINSHAFT
(1) Remove retaining ring that secures synchro-
nizer hub onto mainshaft (Fig. 27). Use standard
(instead of parallel jaw) snap-ring pliers to remove
this retaining ring.
Fig. 24 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 25 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 26 Removing Sector Shaft O-Ring And Retainer
1 - SHAFT BORE
2 - NYLON RETAINING RING
3 - SECTOR SHAFT O-RING
Fig. 27 Synchronizer Hub Retaining Ring Removal
1 - SYNCHRONIZER HUB
2 - RETAINING RING
BR/BETRANSFER CASE - NV241LD 21 - 863
TRANSFER CASE - NV241LD (Continued)

REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bear-
ing if rough or noisy. Check the retainer for cracks or
wear in the bearing bore.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended.
Inspect rear extension bushing. Replace if worn or
scored.
DRIVE CHAIN
Examine the drive chain and shaft bearings.
replace the chain if stretched, distorted, or if any of
the links bind. Replace the bearings if rough, or
noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 45)
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. Replace the input retainer seal, do not reuse it.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.Or the threads can be repaired with HelicoilŸ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
(1) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing from case from inside annu-
lus gear opening (Fig. 46).
(2) Install locating ring on new bearing.
(3) Position case so that the forward end is facing
upward.
(4) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing into case. The bearing
locating ring must be fully seated on case (Fig. 47).
(5) Using Installer 6953, remove front output shaft
bearing.
(6) Start front output shaft bearing in case (Fig.
48). Then seat bearing with Handle C-4171 and
Installer 6953.
(7) Install front output shaft bearing retaining
ring.
(8) Install new front output seal in front case with
Installer Tool 6888 and Tool Handle C-4171 as fol-
lows:
(a) Place new seal on tool.Garter spring on
seal goes toward interior of case.
Fig. 45 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEARFig. 46 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
BR/BETRANSFER CASE - NV241LD 21 - 869
TRANSFER CASE - NV241LD (Continued)

(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)

(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)

(6) Install front sprocket retaining ring (Fig. 81).
(7) Install spring and cup on shift rail (Fig. 82).
(8) Insert magnet in front case pocket (Fig. 83).OIL PUMP AND REAR CASE
Lubricate the oil pump components with before
installation. Prime the oil pickup tube by pouring a
little oil into the tube before installation.
(1) Install new o-ring in pickup tube inlet of oil
pump (Fig. 84).
(2) Position oil pickup tube and filter in rear case.
Be sure pickup filter is seated in case pocket and
that pickup tube is aligned in case notches (Fig. 85).
Be sure hose that connects tube to filter is securely
positioned.
Fig. 81 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 82 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 83 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
Fig. 84 Pickup Tube O-Ring Installation
1 - O-RING (PUMP PICKUP)
2 - PICKUP TUBE
Fig. 85 Oil Pickup Tube And Filter Position In Rear
Case
1 - FILTER
2 - TUBE AND HOSE
3 - TUBE IN NOTCH
BR/BETRANSFER CASE - NV241LD 21 - 879
TRANSFER CASE - NV241LD (Continued)

(3) Install companion flange on front shaft (Fig.
104). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
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. 105).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
Fig. 102 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
Fig. 103 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 104 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
Fig. 105 Transfer Case Shifter
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
BR/BETRANSFER CASE - NV241LD 21 - 887
FRONT OUTPUT SHAFT SEAL (Continued)