2002 DODGE RAM ECU

(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 271).
(13) Remove park rod E-clip and separate rod from
manual lever (Fig. 272).
(14) Remove E-clip and washer that retains throt-
tle lever shaft in manual lever (Fig. 273).
Fig. 270 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
Fig. 271 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 272 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 273 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
BR/BEAUTOMATIC TRANSMISSION - 47RE 21 - 411
VALVE BODY (Continued)

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 289). Then remove the one large diam-
eter and the six smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 291).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 290).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 291).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 278).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 292).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 292).
(9) Remove 1-2 shift control valve and spring (Fig.
292).
(10) Remove 1-2 shift valve and spring (Fig. 292).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 292).
(12) Remove pressure plug cover (Fig. 292).
(13) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 292).
Fig. 288 Rear Clutch and Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 289 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 290 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
21 - 416 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

(c) Hold shuttle valve in place.
(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.
BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 306).(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 306).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 307).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 307).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 308).
(8) Tighten all valve body housing screws to 4 N´m
(35 in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at center
and working outward.
Fig. 304 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
21 - 424 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 309).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 309). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Install 3-4 shift valve and spring.
(4) Install converter clutch timing valve and
spring.
(5) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
(7) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 310). Tighten screws to 4 N´m (35 in. lbs.).
VALVE BODY FINAL
(1) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N´m (35
in. lbs.) torque.
(2) Insert manual lever detent spring in upper
housing.
(3) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with
Retainer Tool 6583 (Fig. 311).
(4) Install throttle lever in upper housing. Then
install manual lever over throttle lever and start
manual lever into housing.
(5) Align manual lever with detent ball and man-
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.(6) Then install manual lever seal, washer and
E-clip.
(7) Verify that throttle lever is aligned with end of
kickdown valve stem and that manual lever arm is
engaged in manual valve (Fig. 312).
(8) Position line pressure adjusting screw in
adjusting screw bracket.
(9) Install spring on end of line pressure regulator
valve.
(10) Install switch valve spring on tang at end of
adjusting screw bracket.
Fig. 308 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWNFig. 309 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
3 - 3-4 SHIFT VALVE SPRING
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 310 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
21 - 426 AUTOMATIC TRANSMISSION - 47REBR/BE
VALVE BODY (Continued)

Condition Possible Cause Correction
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.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and vacuum harness at
transfer case switch.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Remove rear crossmember.
(9) Mark front and rear propeller shafts for assem-
bly reference.(10) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Move transfer case assembly rearward until
free of transmission output shaft.
(14) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
21 - 432 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

MAINSHAFT
(1) Remove retaining ring that secures synchro-
nizer hub onto mainshaft (Fig. 27). Use standard
(instead of parallel jaw) snap-ring pliers to remove
this retaining ring.
(2) Remove synchronizer hub (Fig. 28).(3) Inspect synchronizer hub struts and springs. If
struts appear worn, remove struts and springs from
hub. Note position of springs for installation refer-
ence (Fig. 29).
(4) Remove brass stop ring (Fig. 30). Discard stop
ring if worn, cracked, or any teeth are missing.
Fig. 27 Synchronizer Hub Retaining Ring Removal
1 - SYNCHRO HUB
2 - RETAINING RING
Fig. 28 Synchronizer Hub Removal
1 - SYNCHRO HUB
2 - MAINSHAFT
Fig. 29 Synchronizer Strut And Spring Removal
1 - SYNCHRO STRUTS
2 - SYNCHRO HUB
3 - SYNCHRO SPRINGS
Fig. 30 Synchronizer Stop Ring Removal
1 - DRIVE SPROCKET
2 - STOP RING
BR/BETRANSFER CASE - NV241LD 21 - 439
TRANSFER CASE - NV241LD (Continued)

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)

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).
(4) Install 3 synchronizer struts and 2 springs in
hub as follows:
(a) Insert first strut in hub (Fig. 63). Strut
shoulders rest (and slide) on sides hub slot as
shown.
(b) Insert hooked end of first spring in center of
strut to secure it. Then work spring into hub (Fig.
64).(c) Press spring inward and insert last two
struts in hub slots. Be sure spring is positioned
under struts to properly secure them (Fig. 65).
(d) Turn hub over and install remaining spring
in hub. Position hooked end of second spring oppo-
site the first spring's hooked end.
Fig. 60 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 61 Drive Sprocket Installation
1 - MAINSHAFT
2 - DRIVE SPROCKET
Fig. 62 Synchronizer Stop Ring Installation
1 - BRASS STOP RING
2 - DRIVE SPROCKET
Fig. 63 Installing First Synchronizer Strut And
Spring
1 - FIRST STRUT
2 - SYNCHRO HUB
3 - SPRING
BR/BETRANSFER CASE - NV241LD 21 - 449
TRANSFER CASE - NV241LD (Continued)