Page 1929 of 2255

(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.
(5) Remove support sleeve from carrier (Fig. 36).
(6) Remove rear thrust washer (Fig. 37).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3MŸ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
If any pump component is worn, or damaged, the
pump must be replaced as an assembly.
Fig. 31 Removing Input Gear
1 - BEARING
2 - INPUT GEAR
3 - PLASTIC MALLET
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
21 - 476 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 1930 of 2255

Inspect the spline teeth on the synchronizer hub
(Fig. 38). If evidence of chipping or excessive wear is
apparent, replace the hub. The hooked end of each
synchronizer spring should be inserted in one of the
struts. In addition, the springs should not interfere
with the polished gear cone or inside diameters of
the hub.
Inspect the stop ring for cracks and wear. Replace
the ring if necessary or if doubt exists over condition.
Check a replacement synchronizer ring for proper fit
on the cone with a minimum of wobble. Also check
the synchronizer struts for wear or damage.
Inspect all gear teeth and splines for wear or dam-
age. Also check splines for burrs, or nicks. Removeminor nicks and scratches with an oil stone. Replace
any part with damaged splines.
It is recommended that all retaining rings be
replaced during overhaul. Most of the retaining rings
can be distorted during removal and should not be
reused.
Inspect the two case halves, for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary. How-
ever, stripped threads can be repaired with Heli-
CoilŸ stainless steel thread inserts. The case vent
tube can be resecured with LoctiteŸ 680 if necessary.
Inspect the annulus gear. Be sure the gear teeth
are in good condition. Replace the front case and
annulus as an assembly if the gear is damaged.
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
Fig. 36 Support Sleeve Removal
1 - SUPPORT SLEEVE
2 - PLANETARY CARRIER
Fig. 37 Rear Thrust Washer Removal
1 - REAR THRUST WASHER
2 - PLANETARY CARRIER
BR/BETRANSFER CASE - NV241HD 21 - 477
TRANSFER CASE - NV241HD (Continued)
Page 1931 of 2255

Check condition of the shift fork pads (Fig. 39).
The pads should be replaced if cracked, worn, or
loose (won't stay on fork).
The shift forks, clutch and sleeve should all be
checked for wear, cracks, or any type of damage (Fig.
40). The shift sector shaft and detents should be
inspected for wear. The mode fork and shift rail are a
one-piece unit. If either part is damaged, replace the
fork and rail as an assembly. Replace the shift rail
cup and spring if they exhibit wear.
Inspect the planetary thrust washers (Fig. 41)
carefully for wear or damage. Replace both washers
if necessary.
The planetary carrier cannot be disassembled. It
must be serviced as an assembly if damaged. Check
condition of the pinion teeth and PTO gear teeth. If
pinion tooth wear is evident, it will also be necessary
to check condition of the annulus gear teeth.
Fig. 38 Mainshaft Components
1 - DRIVE SPROCKET 5 - STRUTS
2 - STOP RING 6 - SYNCHRO SPRINGS
3 - SYNCHRO HUB 7 - MAINSHAFT
4 - RETAINING RING
Fig. 39 Shift Fork Pads
1-PADS
2-PADS
3 - RANGE FORK
4 - MODE FORK
21 - 478 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 1932 of 2255
Fig. 40 Shift Fork Components
1 - SUPPORT SLEEVE 5 - MODE FORK AND SHIFT RAIL
2 - RANGE FORK 6 - SPRING
3 - SHIFT SECTOR 7 - CUP
4 - POPPET PLUNGER, SPRING, SCREW 8 - SLIDING CLUTCH
Fig. 41 Planetary And Input Gear Components
1 - LOCK RING 6 - RETAINING RING
2 - THRUST WASHERS 7 - SUPPORT SLEEVE
3 - PLANETARY CARRIER 8 - INPUT GEAR
4 - PTO GEAR 9 - RETAINING RING
5 - BEARING
BR/BETRANSFER CASE - NV241HD 21 - 479
TRANSFER CASE - NV241HD (Continued)
Page 1933 of 2255

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. 42).
(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. 43).
(5) Using Installer 6953, remove front output shaft
bearing.
(6) Start front shaft output bearing in case (Fig.
44). Then seat bearing with Handle C-4171 and
Installer 6953.
(7) Install front output bearing retaining ring.
(8) Install new front output seal in front case with
Installer Tool 6888 (Fig. 45) and Tool Handle C-4171
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. 46). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
(c) Remove installer and verify that seal is
recessed the proper amount. 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 seal posi-
tion.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown. Theseal could loosen, or become cocked if not seated
to recommended depth.
(9) Remove seal from front bearing retainer with
suitable pry tool.
Fig. 42 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 43 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 44 Front Output Bearing Installation
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
21 - 480 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 1934 of 2255
(10) Install new oil seal in front bearing retainer
with Installer 7884 (Fig. 47).
(11) Remove seal from oil pump with suitable pry
tool.
(12) Install new seal in oil pump with Installer
7888 (Fig. 48).
Fig. 45 Front Output Seal Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 6888
Fig. 46 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. 47 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 48 Install Oil Pump Seal
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
BR/BETRANSFER CASE - NV241HD 21 - 481
TRANSFER CASE - NV241HD (Continued)
Page 1935 of 2255

(13) Inspect carrier needle bearing. If bearing is
worn, rough, or damaged in any way, remove it with
a brass punch and hammer (Fig. 49).
(14) Install new needle bearing in planetary car-
rier (Fig. 50). Use Handle C±4171 and Installer 5062
to install bearing.
(15) 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. 51).
(16) Install new pilot bearing with Plug C-293-3.
(17) Remove the output shaft rear bearing with
the screw and jaws from Remover L-4454 and Cup
8148 (Fig. 52).(18) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 53). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 54).
Fig. 49 Carrier Needle Bearing Removal
1 - BRASS PUNCH
2 - CARRIER NEEDLE BEARING
Fig. 50 Planetary Carrier Needle Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5062
3 - CARRIER BEARING
Fig. 51 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 52 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
21 - 482 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)
Page 1936 of 2255
INPUT AND PLANETARY GEAR
(1) Lubricate planetary components with transmis-
sion fluid.
(2) Install first thrust washer in carrier (Fig. 55).
Lube washer with petroleum jelly before installation.
(3) Support carrier with wood blocks under PTO
gear (Fig. 56).
(4) Install support sleeve in planetary carrier. Be
sure sleeve is seated.
Fig. 53 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 54 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 55 Thrust Washer Installation
1 - THRUST WASHER
2 - TABS IN SLOTS
Fig. 56 Support Sleeve Installation
1 - PLANETARY
2 - SUPPORT SLEEVE
3 - WOOD BLOCKS
BR/BETRANSFER CASE - NV241HD 21 - 483
TRANSFER CASE - NV241HD (Continued)