2002 DODGE RAM Service Repair Manual

engine oil capacity fuse diagram seats wipers ECU oil pressure

Load previous 8 pages

Page 1913 of 2255

DODGE RAM 2002 Service Repair Manual EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Usin

Page 1914 of 2255

DODGE RAM 2002 Service Repair Manual FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - R

Page 1915 of 2255

DODGE RAM 2002 Service Repair Manual (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)

Page 1916 of 2255

DODGE RAM 2002 Service Repair Manual (7) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(8) Lower vehicle.(9) Install the bolts to hold the shifter mechanism
to the floor pan.
(10) Install t

Page 1917 of 2255

DODGE RAM 2002 Service Repair Manual (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 locatin

Page 1918 of 2255

DODGE RAM 2002 Service Repair Manual TRANSFER CASE - NV241HD
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241HD
DESCRIPTION........................465
OPERATION..........................467
DIAGNOSIS AND TESTING - TRANSFER
CASE.........

TRANSFER CASE - NV241HD
TABLE OF CONTENTS
page page
TRANSFER CASE - NV241HD
DESCRIPTION........................465
OPERATION..........................467
DIAGNOSIS AND TESTING - TRANSFER
CASE..............................467
REMOVAL............................469
DISASSEMBLY........................469
CLEANING...........................476
INSPECTION.........................476
ASSEMBLY...........................480
INSTALLATION........................494
SPECIFICATIONS
TRANSFER CASE....................495
SPECIAL TOOLS
TRANSFER CASE - NV241HD...........495EXTENSION HOUSING BUSHING AND SEAL
REMOVAL............................497
INSTALLATION........................497
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................497
FRONT OUTPUT SHAFT SEAL
REMOVAL............................498
INSTALLATION........................498
SHIFT LEVER
REMOVAL............................499
INSTALLATION........................500
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER..........500
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.
PTO CAPABILITY
The NV241HD transfer case has power take-off
capability. A PTO gear permanently attached to the
planetary carrier, and a removable PTO cover are
provided for this purpose.
BR/BETRANSFER CASE - NV241HD 21 - 465

Page 1919 of 2255

DODGE RAM 2002 Service Repair Manual Fig. 1 NV241HD Transfer Case
21 - 466 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

Page 1920 of 2255

DODGE RAM 2002 Service Repair Manual IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.

IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
OPERATING RANGES
Transfer case operating ranges are:
²2H (2-wheel drive)
²4H (4-wheel drive)
²4LO (4-wheel drive low range)
The 2H range is for use on any road surface at any
time.
The 4H and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The onlyexception being when the road surface is covered by
ice and snow or other loose, slippery material.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
A front axle disconnect system is used to achieve
two-wheel drive mode. The axle disconnect vacuum
motor is actuated by a vacuum switch on the transfer
case. The switch is operated by the transfer case
range rod.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The synchronizer components allow the transfer
case to be shifted between the 2H and 4H operating
ranges while the vehicle is in motion. The vehicle
must have the transmission placed in NEUTRAL, or
the clutch depressed in the case of a manual trans-
mission, and be moving less than 2-3 MPH when
shifting into the 4L operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
1 - FRONT CASE 16 - NEEDLE BEARING
2 - PLANETARY ASSEMBLY 17 - FRONT OUTPUT SHAFT
3 - SUPPORT SLEEVE 18 - SPROCKET
4 - SYNCHRO HUB 19 - ROLLER BEARING
5 - STOP RING 20 - SEAL
6 - REAR CASE 21 - COMPANION FLANGE
7 - OIL PUMP 22 - SECTOR SHAFT
8 - REAR RETAINER 23 - SLIDING CLUTCH
9 - OUTPUT BEARING 24 - SLIDING HUB
10 - REAR EXTENSION 25 - PTO GEAR
11 - SEAL 26 - ANNULUS GEAR
12 - BUSHING 27 - INPUT BEARING RETAINER
13 - SPEEDOMETER GEAR 28 - SEAL
14 - DRIVE SPROCKET 29 - INPUT GEAR
15 - CHAIN 30 - INPUT BEARING
Fig. 2 Transfer Case Identification Tag - Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
BR/BETRANSFER CASE - NV241HD 21 - 467
TRANSFER CASE - NV241HD (Continued)

Load next 8 pages

Page: < prev 1-10 ... 1881-1888 1889-1896 1897-1904 1905-1912 1913-1920 1921-1928 1929-1936 1937-1944 1945-1952 ... 2256 next >

key power steering service interval open gas tank reset sun roof lights