2001 DODGE RAM torque

(4) Apply MopartSilicone Sealer to threads of rear
retainer bolts. Then install retainer bolts finger tight.
(5) Install output bearing on mainshaft and seat it
in rear retainer with suitable size pipe tool (Fig. 94).
(6) Install output bearing retaining ring (Fig. 95).
(7) Tighten rear retainer bolts to 27-34 N´m (20-25
ft. lbs.) torque.
(8) Install new seal in rear extension housing seal
with suitable size installer tool.
(9) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(10) Align and install rear extension on retainer
(Fig. 96).(11) Apply MopartSilicone Sealer to threads of
rear extension housing bolts. 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
Fig. 94 Output Bearing Installation
1 - OUTPUT BEARING
2 - PIPE TOOL
Fig. 95 Output Bearing Retaining Ring Installation
1 - OUTPUT BEARING
2 - RETAINING RING
Fig. 96 Rear Extension Installation
1 - REAR EXTENSION
2 - RETAINER
3 - EXTENSION SEAL
21 - 882 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

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 - NV241LD 21 - 883
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)

(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. 108).
(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. 108 Shifter Adjustment Location
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
BR/BETRANSFER CASE - NV241LD 21 - 889
SHIFT LEVER (Continued)

TRANSFER CASE - NV241HD
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241HD
DESCRIPTION..........................890
OPERATION............................892
DIAGNOSIS AND TESTING................892
TRANSFER CASE.....................892
REMOVAL.............................894
DISASSEMBLY..........................894
CLEANING.............................902
INSPECTION...........................902
ASSEMBLY............................904
INSTALLATION..........................919
SPECIFICATIONS........................919
SPECIAL TOOLS........................920EXTENSION HOUSING BUSHING AND SEAL
REMOVAL.............................921
INSTALLATION..........................921
FLUID
STANDARD PROCEDURE.................922
FLUID DRAIN AND REFILL...............922
FRONT OUTPUT SHAFT SEAL
REMOVAL.............................922
INSTALLATION..........................922
SHIFT LEVER
REMOVAL.............................924
INSTALLATION..........................924
ADJUSTMENTS.........................925
TRANSFER CASE - NV241HD
DESCRIPTION
The NV241HD is a part-time transfer case with a
low-range gear system. The transfer case provides
three operating ranges plus a NEUTRAL position.
The low range position provides a gear reduction
ratio of 2.72:1 for increased low speed torque capabil-
ity. Operating ranges are: 2H, 4H, and 4LO.
The synchronizer mechanism consists of a brass
stop ring, synchronizer hub, and the sliding clutch(Fig. 1). The synchronizer components allow the
transfer case to be shifted between the 2H and 4H
operating ranges while the vehicle is in motion.
The gear cases, retainer and extension are all of
aluminum. Drive sprockets and an interconnecting
drive chain are used to transmit engine torque to the
front/rear propeller shafts. The mainshaft, input gear
and front output shaft are supported by ball and nee-
dle bearings.
21 - 890 TRANSFER CASE - NV241HDBR/BE

DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.1) Vehicle speed too great to permit
shifting.1) Stop vehicle and shift into desired
range. Or, reduce speed to below 3-4
km/h (2-3 mph) before attempting the
shift.
2) If vehicle was operated for an
extended period in 4H on a dry paved
surface, the driveline torque load may
be causing a bind.2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved surfaces.
3) Transfer case external shift linkage
binding.3) Lubricate, repair, or replace linkage
bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding, worn,
or damaged.5) Disassemble the transfer case and
replace worn or damaged
components as necessary.
Transfer Case noisy in all operating
ranges.1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole
with MoparTATF +4, type 9602,
Automatic Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.1) Transfer case not completely
engaged in 4L position.1) With the transmission in
NEUTRAL, or the clutch depressed in
the case of a manual transmission
and the vehicle moving under 3-4
km/h (2-3 mph), shift the transfer case
to NEUTRAL and then shift into the
4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair linkage
as necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.4) Disassemble unit and repair as
necessary.
5) Low range gear worn or damaged. 5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct level.
2) Vent closed or restricted. 2) Clear or replace vent as necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary. Check
to ensure that another component, the
propeller shaft slip yoke for example,
is not causing damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H position
on hard, dry surfaces.
BR/BETRANSFER CASE - NV241HD 21 - 893
TRANSFER CASE - NV241HD (Continued)

(8) Apply MopartSilicone Sealer to threads of
input retainer bolts. Then install and tighten bolts to
27-34 N´m (20-25 ft. lbs.) torque.
MAINSHAFT
(1) Install drive sprocket on mainshaft (Fig. 64).
(2)
Install brass stop ring on drive sprocket (Fig. 65).
(3) Install 3 synchronizer struts and 2 springs in
hub as follows:
(a) Insert first strut in hub (Fig. 66). Strut
shoulders rest (and slide) on sides hub slot as
shown.
Fig. 65 Synchronizer Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKET
Fig. 66 Installing First Synchronizer Strut And
Spring
1 - FIRST STRUT
2 - SYNCHRONIZER HUB
3 - SPRING
Fig. 63 Input Bearing Retainer Installation
1 - FRONT CASE
2 - INPUT BEARING RETAINER
Fig. 64 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
21 - 910 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)