2002 DODGE RAM Service Repair Manual

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Page 1945 of 2255

DODGE RAM 2002 Service Repair Manual (7) Realign sliding clutch on synchronizer hub if
necessary. Press synchronizer struts inward to ease
realignment. Be sure mainshaft is fully seated before
proceeding.
(8) Install spring and cup on sh

Page 1946 of 2255

DODGE RAM 2002 Service Repair Manual (7) Verify that oil pump is aligned and seated on
rear case. Reposition pump if necessary.
(8) Check stud at end of case halves (Fig. 94). If
stud was loosened or came out during disassembly,
apply Lo

Page 1947 of 2255

DODGE RAM 2002 Service Repair Manual COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 95).
(2) Install companion flange on front shaft (Fig.
96). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs

COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 95).
(2) Install companion flange on front shaft (Fig.
96). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
EXTENSION HOUSING AND PTO COVER
(1) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of extension housing. Keep
sealer bead width to maximum of 3/16 inch. Do not
use excessive amount of sealer as excess could be dis-
placed into oil pump.
(2) Position extension housing over output shaft.
(3) Spread extension housing retaining ring and
seat extension housing on rear case. Verify that the
retaining ring is seated in output shaft rear bearing.
(4) Install retaining ring access cover.
(5) Apply MopartSilicone Sealer, or equivalent, to
threads of extension housing bolts. Then install bolts
finger tight.
(6) Tighten extension housing bolts to 27-34 N´m
(20-25 ft. lbs.) torque.
(7) Apply MopartSilicone Sealer to mating surface
of PTO cover and to cover bolt shanks and underside
of bolt heads. 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. 95 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 96 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
21 - 494 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

Page 1948 of 2255

DODGE RAM 2002 Service Repair Manual 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

Page 1949 of 2255

DODGE RAM 2002 Service Repair Manual Installer, Bearing - 6953
Installer, Seal - 7884
Plug, Extension - C-293-3
Installer, Seal - C-4210
Installer, Bearing - 5062
Installer, Bushing - 5066
Installer, Pump Housing Seal - 7888
Remover, Bea

Page 1950 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 1951 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 1952 of 2255

DODGE RAM 2002 Service Repair Manual (2) Install companion flange seal on front shaft
(Fig. 104).
(3) Install companion flange on front shaft (Fig.
105). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
(4)

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