2002 DODGE RAM Service Repair Manual

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Page 1897 of 2255

DODGE RAM 2002 Service Repair Manual SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 43). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 43). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 44). The
mode fork pads are serviceable and can be replaced if
necessary. The range fork pads are not serviceable.
The fork must be replaced as an assembly if the pads
are worn or damaged.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
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.
Fig. 43 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
Fig. 44 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (NON-SERVICEABLE)
Fig. 45 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 444 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

Page 1898 of 2255

DODGE RAM 2002 Service Repair Manual 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.

Page 1899 of 2255

DODGE RAM 2002 Service Repair Manual (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
s

Page 1900 of 2255

DODGE RAM 2002 Service Repair Manual (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 pilo

Page 1901 of 2255

DODGE RAM 2002 Service Repair Manual (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

Page 1902 of 2255

DODGE RAM 2002 Service Repair Manual SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Install drive sprocket on mainshaft (Fig. 61).
(3) Install brass stop ring on drive sprocket (Fig.
62

Page 1903 of 2255

DODGE RAM 2002 Service Repair Manual (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 synchronize

Page 1904 of 2255

DODGE RAM 2002 Service Repair Manual (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.
(

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