2002 DODGE RAM oil

²flange head bolts to 47-61 N´m (35-45 ft. lbs.)
²all other bolts/nuts to 27-34 N´m (20-25 ft. lbs.)
(10) Install rear output bearing and snap-ring to
output shaft.
COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 90).
(2) Install companion flange on front shaft (Fig.
91). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
Fig. 87 Rear Case And Oil Pump Installation
1 - MAINSHAFT
2 - OIL PUMP
3 - REAR CASE
Fig. 88 Shift Rail Seated In Rear Case Bore
1 - REAR CASE
2 - SHIFT RAIL
Fig. 89 Washer Installation On Case Stud And
Dowel Bolts
1 - CASE STUD/BOLT
2 - WASHER
Fig. 90 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 91 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
21 - 456 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

(11) Apply MopartSilicone Sealer to threads of
rear extension housing bolts. 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
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 35-46 26-34 -
Bolt, Front Brg. Retainer 16-27 12-24 -
Bolt, Case Half 35-46 26-34 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 20-25 -
Bolt, Rear Retainer 35-46 26-34 -
Nuts, Mounting 30-41 20-30 -
Bolts, U-Joint 19 17 -
Vacuum Switch 20-34 15-25 -
21 - 458 TRANSFER CASE - NV241LDBR/BE
TRANSFER CASE - NV241LD (Continued)

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)

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.
EXTENSION HOUSING
(1) Remove extension housing snap-ring access
cover.
(2) Remove bolts holding extension housing to rear
case half.
(3) Tap extension housing with plastic or rawhide
hammer to loosen sealant.
(4) Disengage extension housing snap-ring from
rear output shaft bearing.
(5) Separate extension housing from transfer case.
COMPANION FLANGE AND SHIFT LEVER
(1) Shift transfer case into NEUTRAL.
(2) Remove companion flange nut (Fig. 3). Discard
nut after removal. It is not reusable.
(3) Remove companion flange from front output
shaft. Use a suitable puller if flange can not be
removed by hand.
(4) Remove companion flange rubber seal from
front output shaft (Fig. 4).(5) Remove nut and washer that retain shift lever
to sector shaft. Then remove shift lever from shaft
(Fig. 5).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove output bearing retaining ring with
heavy duty snap-ring pliers.
(2) Remove output shaft bearing.
(3) Note position of bolts that attach rear case to
front case (Fig. 6). Some bolts/studs at ends of case
Fig. 3 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - 1-1/8º SOCKET
Fig. 4 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 5 Shift Lever Removal
1 - SHIFT LEVER
2 - NUT/WASHER
BR/BETRANSFER CASE - NV241HD 21 - 469
TRANSFER CASE - NV241HD (Continued)

require flat washers. Mark position of these bolts
with paint or scriber.
(4) Remove rear case-to-front case bolts.
(5) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 7).(6) Unseat rear case from alignment dowels (Fig.
8).
(7) Remove rear case and oil pump assembly from
front case.
(8) Remove shift rail cup and spring (Fig. 9).
Fig. 6 Removing Case Attaching Bolts
1 - REAR CASE
2 - STUD
3 - NUT AND WASHER
4 - SOCKET
Fig. 7 Loosening Rear Case (Breaking Sealer Bead)
1 - SLOT
2 - REAR CASE
3-PRYTOOL
Fig. 8 Removing Rear Case From Alignment Dowels
1 - CASE DOWELS (2)
2 - REAR CASE
Fig. 9 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
21 - 470 TRANSFER CASE - NV241HDBR/BE
TRANSFER CASE - NV241HD (Continued)

(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)

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)

(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)